The best weld. Welding seams

To learn how to weld well, you need to practice a lot. There are an incredible number of moments when you need to weld by welding, and this may be required at home, in a country house, in an apartment, in a garage, in any high-rise building, in particular in such areas as construction or home repairs, as well as in plumbing, water supply and drainage installations and more. Hiring specialists to carry out welding work is not a cheap pleasure, and therefore many people prefer to weld the necessary elements themselves. How to do it right? Learning to work with electric welding from scratch is not easy, but it is quite possible, and for this you can attend lessons for beginners, purchase a tutorial for dummies, or use the tips presented below.

• • Recommendations: how to weld metal correctly
  • Welding seam options
  • Tips: how to learn to weld by yourself
  • What defects are worth knowing about in order to make the correct welding seam?
  • Precautions before welding with electrodes
  • Nuances for beginners in welding
  • How to cook using electric welding (video lessons)
  • Examples of welding seams (photo)

To weld metal sheets or pipes, you will need to familiarize yourself with safety precautions, study the work process, carefully follow the technology, or hire a welder such as a trumpeter.

Many people think that it is enough to learn how to use electrodes and how to weld seams, but you need to know all the intricacies of the work, especially regarding the connection of 2 different metals and what electrodes are needed.

Before you start welding metal, you need to read the recommendations of specialists and watch a master class

Theory is one thing, but a course of practice is required to begin independently welding various structures without mistakes and the likelihood of leaks. For example, before welding, each element must be fixed using ties, clamps and other elements.

Need to know:

• What problems may arise;
• How to avoid defects;
• What is the welding technology for a specific type of element?

In addition, tack welds or, in other words, transverse seams, each of which holds the joints together, may be required, and it is advisable to install them at a distance of 10 cm from each other.

Welding seam options

Exist Various types seams, which may differ from each other in various factors, in particular by how the connection is made metal products. These are the very basics of welding that are taught to beginners.

The seam can be:

• Butt;
• Overlap;
• Tavrovy.

Welding seams may vary depending on the type of welding machine

The profession of an electric welder is very complex and sometimes requires too much large investments in terms of strength and energy, since welding of metal products can be carried out even under the ceiling. The classification of seams can be based on where they are located in space, and there are vertical, horizontal, and ceiling types.

Tips: how to learn to weld by yourself

It is quite possible to weld a metal structure yourself in 1 day if you know how many electrodes are required, which ones should be used, and provided that the product is not too large.

What else do you need to keep in mind to learn how to cook on your own:

1. For a welder, it is important not only to work correctly, but also to learn the basics, in particular what operating mode is required for a particular material, since the metal can be made of steel, alloys or fabrics such as metal.
2. You should definitely study the methods by which you can make a specific seam.
3. You need to choose the right electrodes and welding wire.

If you initially do not need to become a professional of the highest category, then you can learn welding yourself by watching video tutorials, drawings with seams, and also studying the advice of professionals. The training will be long, but possibly productive, especially if you gradually try to produce seams, increasing the amount of work experience.

To start welding, you need electrodes and the welding machine itself.

To learn how to weld well, you should get the appropriate education.

Many people prefer to use resanta, as the equipment can withstand long-term loads, which allows you to quickly finish the job. When first trying to work with welding, it is better to use an inverter, and only then, with a lot of experience, it is possible to use any other device. As for the electrodes, it is advisable to choose “3”. They are easy to use, and most importantly, they do not overload the electricity network.

In general, welding equipment is divided into types - transformer, rectifier, inverter. Why do inverters remain popular? They are compact in size, light in weight, and very easy for a beginner to handle. When taking the first steps to learning welding, it is worth taking more simple types metal and preferably even elements, so as not to complicate the task.

Before welding you need to prepare:

• Bucket with water;
• Hammer for knocking down slag;
• Iron brush;
• A mask that protects the face and neck area;
• Gloves made of special fabric impregnated with a composition to prevent fire and burning of the fabric;
• Special clothing with long sleeves.

Do not forget that welding is a fire hazard, and therefore it is strictly forbidden to have combustible or flammable objects nearby in order to avoid serious consequences.

What defects are worth knowing about in order to make the correct welding seam?

Making beautiful seams that look perfect is not so easy, since even a specialist with extensive experience cannot always carry out the process as competently as possible. Everything depends not only on whether the rules are followed and whether the angle of inclination of the electrode is chosen correctly, but also on many other factors.

It is worth noting that any training manual contains data on defects, which you must familiarize yourself with.

The correct welding seam looks neat and practically does not differ in thickness in different places

There are critical ones, and there are non-critical ones, that is, those that can be left without additional processing. We learn how to distinguish a high-quality seam from a low-quality one and why defects occur.

Defects:

1. Lack of penetration is a defect in which the joint space is insufficiently filled with liquid metal, this affects the strength of the joint. The reason may be low voltage or too high a speed at which the electrode moves. After the current has been adjusted and the arc has been shortened in length, the defect should be eliminated.
2. Undercut This defect indicates the presence of a groove running along the seam. The reason may again be too long an arc, due to which the seam is not just bad, but wide. This leads to incomplete heating of the metal, due to which the edges begin to quickly harden. To fix the problem, it is worth reducing the arc length and increasing the current.
3. Burns are through holes at the joints. The reason is a high current if the electrode is moved slowly, and too large gaps between the ends of the parts. The defect can be eliminated by correcting the welding mode.
4. If pores form on the seam, randomly scattered along the entire length of the joint, this is due to the presence of a draft in the room, due to which the gas cloud is blown away from the work area, or if the metal is covered with rust.

There are other defects in the form of cracks, or the seam simply bursts; this occurs immediately after the metal has cooled. They can be longitudinal and transverse. Depending on when they formed, they can be cold or hot.

Precautions before welding with electrodes

Regardless of where do-it-yourself manual electric arc camping welding is used, safety precautions must be observed, which is reflected in every welding textbook.

Precautions:

1. It is strictly forbidden to use arc welding in cold weather or in rooms with high humidity.
2. A mask and protective shield must be present to protect your eyes from burns.
3. Clothes must be specially impregnated to prevent sparks and drops of hot metal from rolling off.

When welding metal, be sure to use a protective mask.

Hands should be covered with suede gloves or special canvas mittens. Due to the fact that welding work is carried out at high temperatures, and the likelihood of fire is very high, the process should be carried out where there is water or a fire extinguisher nearby.

Nuances for beginners in welding

There are many tips on welding and even each master has his own secrets, but there are a number of general instructions, guided by which, you can carry out work and lay seams almost professional level, even with self-study.

Nuances:

1. You definitely need to remember about grounding, namely, there is a special clamp that needs to be tightly applied to the part.
2. Be sure to check the cable insulation and how carefully it is tucked into the part.
3. As soon as the ground is connected, the current strength is selected, it depends on the type of electrodes and the material.
4. Before lighting the arc, you need to install the electrode relative to the material at an angle of 60ᵒ.

The principle of welding and the work flow diagram are not too complicated. Namely, if you start moving the electrode slowly over the metal, sparks will begin to form, which indicates the formation of a welding arc. For this to occur, the electrode must be held so that the space between it and the canvas is 5 mm.

During work, the electrode will burn out, but there is no need to rush to move it.

Beginners need to make small welds first

The speed at which the seam needs to be applied depends on whether it should be thin or thick. If the electrode gets stuck, simply move it away or tilt it to the side. The technique is simple but effective. It is worth noting that there is such a term as a weld pool, and it can have different sizes. For example, width 8-15 mm, length 10-30 mm, depth 6 mm.

The format depends on:

• Location – indoors or in space;
• Welding mode;
• Configurations of each connected part;
• Edge size and shape;
• Arc movement speeds.

Welding techniques can be used to make a heating boiler or to connect water pipes. There are simply many places where welding equipment can be used, as it is used to erect fences, make playgrounds, assemble metal structures of high-rise buildings, install drainage systems, install railings and more.

Having not only the skills to work with welding equipment, but also the appropriate education, you can equip your home or site with all the necessary facilities, as well as get a prestigious job. Naturally, those welders who have a complete understanding of their work, welding modes, features and nuances of this matter are held in high esteem.

How to cook using electric welding (video lessons)

It is very easy to distinguish a beginner from a professional, since he will not be too hasty and will have to digest the seams more than once. If high-quality welding work is required, but there is not enough experience or knowledge, then it is better to entrust the process to professionals who are able to carry out everything correctly. top level and at the same time provide a guarantee of quality.

Examples of welding seams (photo)

Today the following types of electric arc welding are known:

At home, these types of welding are practically not used. Therefore, let’s move on to consider the fourth type of welding work - manual electric arc welding.

Manual arc welding is based on the use of a special electrode in a coating

Electric welding machines for manual welding are divided into two types - alternating current and direct current. The use of alternating current allows the design of devices with high performance and power. The advantage of direct current, due to the lack of polarity reversal, is a smoother weld with less metal spatter.

In 1802 V.V. Petrov discovered the phenomenon of galvanic voltaic arc.

A device for welding metals using “electrohephaestus” was patented in 1882 by N.N. Benardos.

Russian engineer N.G. Slavyanov first used an electrode for welding in 1888.

In 1932, Soviet physicist K.K. Khrenov. Successful welding of metals under water was carried out.

Subsea pipeline repair

The operation of the welding machine is based on the creation of an electric arc at the point of contact of two metal parts. High temperature (up to 7000 o C) melts the material to a liquid state and diffusion occurs - mixing at the molecular level.

The fundamental difference between welding and gluing is the absence of auxiliary materials - the parts being joined are transformed into a monolithic structure.

Therefore, it is necessary to clearly understand that for the correct application of welding, only homogeneous metals can be used. You cannot weld aluminum to iron or copper to stainless steel. Melting point different materials different, and the creation of alloys is not included in the range of capabilities of welding equipment.

There are various welding machines for welding iron structures.

The main advantage of inverter welding is the improvement of the dynamics of the electric arc, as well as a noticeable reduction in the weight and dimensions of the installation (compared to direct transformers). In addition, it became possible to smoothly regulate the output current, which significantly increased the efficiency of the unit and ensured ease of ignition of the arc during operation.

But there are also disadvantages:

• temporary limitations in use due to heating of the electronic conversion circuit;
• creation of electromagnetic “noise”, high-frequency interference;
• negative influence of air humidity, which leads to the formation of condensation inside the device.

What is needed for work

Before you start welding, you need a welding machine and equipment:

The place where welding work is carried out is cleared of flammable materials and equipped with fire extinguishing means - water, sand, technical soda. If this is an enclosed space, it is necessary to arrange supply and exhaust ventilation.

Necessary fire-fighting equipment at any site

How to cook by welding

To successfully master the technique of permanently joining metal parts, you need to master 4 basic skills, without which not a single “welding session” is complete.

Setting up the device

The basis for setting up a welding machine is the correct selection of current and voltage output to the terminals. Despite the simplicity of the formulation, the topic of customization deserves a separate discussion. But if we briefly formulate the setting criteria, we can distinguish 5 main parameters:

In order to accurately select the current value, the easiest way is to use ready-made tables.

But due to the fact that each device has its own design features and technological nuances, final word still remains with the “scientific poking method” - the empirical selection of the required current experimentally.

Setting the welding current depending on the electrode diameter

Table of relationship between electrode and welding current

Current selection mode for welding standard butt joints:

A one-sided seam connects the surface of parts on one side, a double-sided seam connects the surface of parts on two opposite sides.

Examples of welding parts using various seams

You can also use a universal table for a wide range:

A simple rule is easy for a novice welder to remember. If the current exceeds the required value, the electrode will burn through the workpiece. If the current is lower than necessary, the part is not welded, the deposited metal falls off when exposed to mechanical means.

Electrode connection

The electrode can be connected to the positive or negative current output. If “+” is connected to the part, then the polarity is called straight. If “-” - reverse. Accordingly, with direct polarity there is a “minus” on the electrode, and with reverse polarity there is a “plus”. The difference between these positions is that more heat is always generated at the “positive” terminal. Experienced welders use this phenomenon to solve specific problems. For example, by manipulating the polarity, you can cook thin sheet steel stainless steel, sensitive to overheating. To do this, “plus” is applied to the electrode, and “minus” is applied to a sheet of thin metal.

One of the electrode connection options

Video: direct and reverse polarity when operating an inverter welding machine

Creating an Arc

The welding process begins with the ignition of an electric arc. In all types of manual welding, the arc is created by briefly touching the electrode to the part. In this case, the end of the electrode is sharply heated to a temperature sufficient to establish an arc discharge.

The process of igniting an electrode arc requires certain skills

After a short circuit, if the arc ignites, it is necessary to maintain a distance between the end of the electrode and the part of 3–5 mm. In this case, it is necessary to take into account the fact that the length of the electrode decreases as welding progresses. When exceeding a distance of 5 mm. the arc is interrupted when the decrease is less than 3 mm. the electrode may stick to the workpiece or cause large splashes of molten metal.

Electrode movement

To create a good seam, various arc patterns have been developed along the welded area. In this case, it is considered important not only to melt the edges of the parts being welded, but also to fill the weld pool with the required amount of metal deposited from the electrode.

Various options electrode end trajectories

This can be achieved by maintaining a constant length of the electric arc and systematically moving the end of the electrode along a certain trajectory.

When producing a seam without transverse movements, the width of the joint is usually equal to b = (0.8–1.5)xd el. Where b is the width of the welded joint, and d is the diameter of the weld

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Today there are many different ways of joining metal products. They can be divided into two groups:

1. Detachable.
2. One-piece.

Classification of welding seams.

The connections of the first group include parts that can be separated without disturbing the connecting elements, for example, a bolt with a nut. It is the second connection that is the most reliable. In this case, the parts cannot be separated without breaking the connecting part. We are talking about welding and riveting joints. When it is necessary to obtain a high-quality and reliable connection, a welding seam is considered the best. Many people buy welding machines to weld parts, but have absolutely no experience. After several unsuccessful attempts they have a question: how to properly lay a welding seam? To do this you need to know a few basic rules.

Main characteristics

The welding process is the joining of metal using electric arc welding. The connected parts are melted using an electric arc, as well as an electrode consisting of a metal rod with a special coating. The quality and reliability of the weld is influenced by many different factors:

Covered metal electrode welding diagram.

• welding machine;
• current adjustment;
• electrode size;
• welder's professionalism.

Types of welding that are used in everyday life and industry are divided into several groups:

• gas press;
• contact;
• roller;
• electroslag;
• termite;
• friction welding.

When to use gas press welding, an open flame of acetyl oxygen is used. The positive side of this method is considered to be high productivity. This method has become widespread in the gas and oil industries. It often occurs when pipelines are laid. This method is also widely used in mechanical engineering.

Resistance welding occurs at low voltage but high value electric current. This method can be used for spot and butt welding.

Semi-automatic welding circuit diagram.

To master technological process To carry out welding work, first of all, you need to have the appropriate welding equipment. You can rent it or buy it. Today, stores offer a wide range of welding machines that have a device that makes it possible to adjust the current strength. A home craftsman can make a welding machine himself, but he cannot do without a converter electrical energy. These devices come in several varieties.

Some types of devices for high-quality work

Transformer. Designed to produce direct current when you have to use a household outlet. When purchasing such a unit, you must always remember that inexpensive models are not able to maintain stable operation of the electric arc. Voltage leakage occurs very often. The negative side is also their mass; they are heavy and clumsy.

Rectifier. This is a device that converts household current into direct current. The device differs from a transformer in the stable operation of the electric arc. The quality of the weld is quite high.

Inverter. The latest converter that allows you to work on any type of current. Always gives high quality welding The seams are even and smooth. The device is very compact, light weight, and easy to light. The inverter is characterized by high performance and speed.

For normal operation of electric welding, there must be a stable arc. This consistency depends on the right choice gap between the part being welded and the electrode coating. The arc burns best when the gap is 5 mm.

Technique for making welds.

The high temperature of the arc causes the part and the metal rod of the electrode to melt. At this time, all the depressions that were formed as a result of melting are filled. When the electrode moves slowly along the surface of the seam, voids are filled.

In order to be proud of the resulting seam, you need to choose the right electrode. To do this, you need to know the metal composition of the part that will need to be welded. The selection of an electrode is based precisely on these parameters. Electrodes are manufactured in several types. They can be:

• steel;
• copper;
• cast iron;
• bimetallic;
• brass.

By marking the electrode, you can determine the viscosity of the resulting weld; the numbers will tell you about the hardness of the metal. The main rule when choosing an electrode is its size. It must match the thickness of the metal.

For high-quality electric welding, so that the seam looks neat and durable, it is necessary to select the correct inclination of the electrode. Typically this angle is 75 degrees relative to the direction of the electric arc. In order for an arc to appear, you need to strike the surface of the metal and, when a flash appears, quickly lift the electrode. When the arc appears, it must be slowly drawn along the seam. An arc will also occur when the electrode is tapped on the surface.

To obtain a stable arc, the current must be adjusted correctly. If it is insufficient, the arc will go out very quickly, and the electrode will “stick”. When the current strength is high, the metal splashes in all directions and it begins to burn.

During operation, the electrode melts and gradually decreases in size. In this regard, you need to constantly move it towards the part, maintaining the required distance for a stable arc. If this is not done, the arc will quickly go out.

During the welding process, a weld pool is formed, which is a liquid mixture of molten metal and a melting coated metal core. When there is a constant smooth movement of the electrode with a maintained gap, the quality of the seam will be the most reliable, and the mechanical performance will be at its best. The seams will look aesthetically pleasing.

After welding, slag is formed over the entire surface of the seam.

It is removed with small blows of a hammer. Then the seam is cleaned with a wire brush. To learn how to weld metal well, you need constant training and a desire to get excellent quality work. Before you start working on your own, it’s worth watching how experienced welders work.

Of course, welding is a very complex and difficult job. It is almost impossible to instantly master all the nuances of this matter. It will take a lot of time to master all the tricks of welding. When you have experience and work skills, it will be possible to obtain original and beautiful products.

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Welding ceiling seams. Sequence of work.

Ceiling welding seam is considered one of the most complex types welding, since the weld pool is located upside down. Welding ceiling seams requires a precise sequence of all actions. If you do not follow the rules and recommendations, you can get a poor-quality connection, which can lead to leaks of hot metal.

When making a ceiling seam, you need to follow safety precautions and protect your face and hands from possible contact with hot drops of metal.

Features of the ceiling seam technique

Note! Preparatory work before welding ceiling seams is accompanied by a number of difficulties. This is due to the fact that during the welding process, molten metal can flow down and accidentally fall on the skin of the person performing the weld. That is why experienced specialists, knowing how to weld such a seam, use special welding techniques that ensure strict compliance with safety rules.

Before connecting ceiling seams, you must clearly understand all the requirements and not neglect to fulfill the mandatory conditions. This information is especially important for novice welders.

If your workpieces are more than one centimeter thick and you do not know how to weld a ceiling seam, then know that in such a situation welding must be done in stages. At the very beginning of work, you need to use an electrode whose diameter does not exceed 3 mm; at all other stages, an electrode with a diameter of 4 mm is used.

Note! Welding a ceiling seam involves creating not only horizontal seams, but also connections along a certain slope (from 10 to 80°C). In this case, both manual welding and semi-automatic welding can be used. You can also use arc welding using coated electrodes.

As already noted, the main distinctive feature Such welding is based on an inverted weld pool and holding the hot metal by tensile force. It is very important to maintain the minimum size of the bath and sometimes move the electrode to the side so that the metal has time to cool and set. In addition, this welding method will protect your connection from cracks.

Welding methods

• Crescent, this method involves placing the electrode at an angle of 90-140° to the surface. Using oscillatory movements in an arc, it moves from edge to edge.
• Ladder, here the electrode is placed in exactly the same way. It is taken away from the hot metal and returned back.
• Back-and-forth method. In this case, the electrode must be constantly returned to the frozen seam.

The first method is considered the simplest and is well suited for inexperienced welders. Options involving ladder and back-and-forth welding are more complex and time-consuming. But such a connection will be of better quality.

Stages of work execution

Initially, the places that will be welded must be well treated by cleaning the edges with a grinder or a metal brush. Then the root of the seam is welded with an electrode (3 mm). Through it, a roller of molten metal is formed. If it is necessary for the roller to be on the reverse side, then the electrode is directed into the gap in small short throws. Monitor and control the uniform arc burning. The resulting roller must be freed from slag. If its shape is too convex, then it is necessary to bring it to pure metal. As already mentioned, in the following stages an electrode with a large diameter (4 mm) is used.

In order to obtain a reliable and durable seam, all safety regulations must be followed. Not only the quality of the seam, but also your personal safety depends on compliance with the rules.

• Be sure to insulate all wires, and when you pause work, completely turn off the welding machine. This way you will protect yourself from electric shock during the welding process.
• It is recommended to weld ceiling seams in a warm, dry room.
• Under no circumstances should you work in rainy or snowy weather. Only specialists with extensive experience should carry out welding in wet areas, but even then you should be extremely careful.
• Wear special protective clothing, a mask and goggles. The entire body should be tightly covered with clothing.

In conclusion, it is worth noting once again that welding ceiling seams is a rather labor-intensive and energy-consuming process. It is quite difficult for a novice welder to make this type of connection. In order to do the job efficiently and create a good, strong seam, you need to gain special knowledge, master the technique of working with a welding machine and become familiar with all the nuances of this type of work. It’s better to practice welding some parts first. If you do not have enough knowledge and experience, then it is better to entrust this process to specially trained people. In any case, both experienced welders and beginners must strictly follow safety rules. Accurate compliance with all requirements and instructions is the key to your personal safety.

How to weld properly. How to place a welding seam correctly

One of the most inconvenient and difficult positions for welding is the ceiling. But it is worth mastering this type of connection due to the automatic increase, which has learned to apply high-quality sutures in such a spatial position. This is in demand at enterprises whose activities are related to laying, and at construction sites. This skill is also useful in everyday life, when welding heating or gazebos. Some elements of a metal garage cannot be assembled without welding joints at the top. How to weld a ceiling seam using electric welding? What are the main precautions and optimal device settings?

Many welders do not like ceiling seams because of the difficulties in their execution. A beginner’s results can often be poor, which discourages them from learning. But if you understand the main problems and prevent them as much as possible, then pretty soon, after training, you can master this difficult connection.

Welding a ceiling seam with an inverter or transformer is significantly different from working on a similar product in the lower position. When metal is welded on the floor, the weld pool spreads over the joint, and the welder only needs to ensure that the joint is properly filled, preventing slag from getting in front of the pool. When the ceiling serves as the working surface, the molten metal tends downward under its own weight.

The slag, being in a liquid state, also constantly drips, which interferes with the welding. These splashes hitting the ground scatter even more, hitting the welder and surrounding objects. The main difficulty when arc welding in the ceiling position of the seam is connecting the sides of the product. A weld pool forms on one edge, but there is no way to bond both sides with metal.

Welding of ceiling seams is carried out at a reduced current, which leads to frequent sticking of the electrode and lack of penetration. One more. The body position with the head thrown back and the arm raised up quickly tires the welder. Therefore, frequent breaks are simply necessary for quality work. Understanding these complexities will help you tune in to the challenges and take steps to make the process easier to implement.

Ceiling welding technology

To understand how to properly perform this type of connection, you need to know the basic rules used by experienced welders. Additionally, you can see how to weld a ceiling seam using electric welding in the video. Here are the main points:

• The sides to be welded should be brought together as much as possible. Welding with gaps on the ceiling is only available to experienced specialists, so the more tightly the parts are connected, the easier it will be to apply the seam.
• Edge cutting is carried out as in the lower position. When the thickness of the sides is more than 5 mm, a V-shaped bevel is made.
• The electrode is brought to the ceiling at an angle of 45 degrees relative to the upper plane. Beginner welders can try welding with half of the electrode, as this will allow better control of its tip and control the formation of the seam.
• The welding process and the seam itself in this spatial position are possible due to the surface tension of the metal. To prevent drops of molten iron from flying off before they catch on the edge, the current should be reduced.
• If the sides are closely brought together, then the first seam on even plates can be made without oscillatory movements. This will fill the joint well. The second pass is made wider to strengthen the ligament. But on pipes it is better to immediately weld with a wide seam.
• Electrode welding can be performed in several ways: crescent, horizontal figure eight, or spiral. When there is a small gap, an intermittent arc is used to allow the deposited drop of metal to cool. After a moment, without allowing the red color to pass through (this can be seen through the mask), the next drop is applied. This is a long process, so the welder does not need to rush and needs to rest periodically.
• Do not be intimidated by the appearance of the connection after the work is completed. Slag can flow down several tiers. But after beating it off, a high seam should remain. Sagging and large rollers are not critical.

Devices and electrodes

Ceiling seams can be made using an inverter or a conventional transformer. It is important to correctly set the current strength, which is 25% lower than when welding on the floor. For example, for plates 5 mm thick, 100A is sufficient. It will be easier to work if the cable is not heavy. This will make it easier to control the end of the electrode and your hand will get less tired. You can also loop the cable around your hand to reduce the strain on your wrist.

Electrodes for ceiling welding are suitable with a diameter of 3 and 4 mm. It is important to use them to reduce the amount of splashing. If beginners use short electrodes, this will allow them to manipulate the arc more confidently.

Precautionary measures

For ceiling seams, you should wear a thick jacket and trousers. Gloves must cover the cuffs, otherwise scale will reach the elbows and burn the skin. A hat or cap without a visor is required on the head. It is important to choose trousers of such length that they cover the collar of the shoe to prevent molten particles from getting inside.

Since the spray hits the ground and spreads further, there should be no flammable objects nearby. You need to use safety glasses to beat off the slag, because it will fall down on the welder. Frequent rest will allow you to relieve stress from the muscles of your neck and arms and get the job done efficiently.

Welding in the ceiling position is not mastered immediately. It takes practice and patience. It’s good to take a few minutes a day and weld two pieces of pipe or corner to the table and try to weld them from below. Having mastered this method, you can safely weld pipes and metal structures of any complexity.

› How to weld using electric welding correctly: weld metal pipes and make beautiful seams.

A weld is one of the most reliable ways to connect parts. It is used in industry and in normal daily life. Every House master Uses welding from time to time. It’s good if he knows how to cook himself, but he often has to turn to specialists. But welding is quite possible to learn. You should start with the simplest: electric welding for beginners is, first of all, learning how to make various seams. More complex work can be done only after gaining experience. Let's look at the basics of technology and some of the tricks of the welding process. Where to start - the preparatory stage FIRST All you need to do is prepare the equipment. You will definitely need a welding machine, a set of electrodes, a hammer for knocking down slag and a brush. The diameter of the electrode is selected depending on the thickness of the metal sheet. Don't forget about protection. We prepare a welding mask with a special light filter, thick clothes with long sleeves and gloves, preferably suede. You will also need a welding rectifier, transformer or inverter - devices that convert alternating current to the constant required for welding. Before work, it is necessary to prepare protective equipment, which includes a special mask with a light filter, suede gloves and long sleeves, as well as Necessary tools Welding process technology Welding is a high-temperature process. To carry it out, an electric arc is formed and held from the electrode to the workpiece being welded. Under its influence, the base material and the metal rod of the electrode melt. As experts say, a welding hole is formed

The modern welding process is a high technology with classification and quality criteria. Since the main final product is welding seams, they are also well described, classified and have their own quality criteria and methods of execution.

Standards in the form of GOSTs contain comprehensive information and symbols of options for a wide variety of purposes.

To begin with, let’s define the concepts of “welding seam” and “welding joint”, because some sources consider them as one and the same thing, others differ in the formulations.

The shortest definition: is a permanent connection by welding.

The second option reveals the physics of the welding process as such: a weld is a section in which two or more parts are connected as a result of crystallization or deformation of a substance, or one and the other together. One way or another, it is more logical to take welding seams and joints as one and the same process.

One of the oldest and most famous standards among specialists is “GOST 5264 - 80 Manual arc welding. Welded connections." This GOST was put into effect back in 1981, it still copes with its tasks perfectly: the main types of welds, their sizes, structural elements and instructions on how to correctly lay a weld are clearly listed. An excellent example of a document that does not need adjustments over time.

Types of welding seams

Types of welding joints.

Like welding methods, types of welding seams fall under a strict classification according to different criteria:

• The method of connecting parts;
• Position during welding;
• Length ;
• Location of the force acting on the seam.

The most popular and important types of seams are grouped according to the method of joining parts:

1. Butt.
2. Angular.
3. T-bars.
4. Overlapping.

Important! Whatever type of weld seam you choose, you need to remember and follow one simple rule: no rust on the metal! Pre-treatment with a file or sandpaper mandatory, the issue is no longer discussed.

Butt seams

Classification of electrodes for welding.

Kinds welded joints include as very popular methods, and rare. Butt methods can be considered highly popular: they are used when welding sheet metal or pipe ends. The fundamental requirement for the butt method is rigid fixation of the parts to be joined with a gap of 1 - 2 mm, which is filled with metal during the welding process.

The most important “butt” issue is the edges of the parts that will melt and join. Or rather, the way to process these edges. The butt connection is considered one of the most reliable and economical in terms of strength. This is especially true when cooking on both sides. Preliminary preparation of the edges is an important component of a high-quality seam. All 32 types of butt joints with edge processing options are set out in the GOST 5264-80 standard.

Here are some examples:

1. If the metal sheet is thin - less than 4 mm, no pre-treatment is required, this is a family with symbols C1, C2, C3.
2. If the sheet thickness is between 4 and 12 mm, the seam can be welded on both one and both sides. But in this case, edge processing by stripping is necessary. It all depends on the requirements for welding quality. If you choose to weld on one side, you will have to make multiple passes to fill the seam. If high quality is required, you need to peel and cook on both sides. Strippings come in the form of V or U. There are many options, all are listed in GOST, for example, symbols C28, C42.
3. If the metal sheet is thicker than 12 mm, only double seams are used with edge processing on both sides in the form of the letter X. V or U shapes for stripping edges with large thicknesses are unprofitable: too much metal will be required to fill them. And this reduces the speed of the process and increases the consumption of electrodes. Symbols C27, C39, C40.

There is no need to outline in this review all possible methods of welding metals using the arc method, depending on the thickness of the sheets and methods of processing the edges; no one will do this better than GOST 5264-80. Therefore, the most correct decision would be to refer to it and recommend this wonderful example technical instructions for careful study.

In short, according to GOST, the joint family is divided into:

• Single-sided and double-sided without edge treatment;
• With processing of one of the edges;
• With processing of both edges;
• Sawing in the form of a V or X;
• With double-sided processing of both edges.

T-joints

The T-beam method is cut into the shape of a “T”: the end of one part is welded to the side surface of another part. Most often, the elements are located perpendicular to each other. GOST 5264-80 describes 9 T-type types: T1 to T9. For a high-quality T-joint, deep melting is required, which is performed using automatic welding. If welding, careful processing of the edges is required.

An interesting feature of deep fusion T-welds: they are stronger than the base metal. The strength of fillet welds (see below about them), on the contrary, is less than the base metal. These kinds of differences must not only be taken into account, but calculations must be made in advance. The concept of “calculation of welded joints” is included in a special section technical mechanics, which is studied in engineering faculties.

These strength-of-materials tasks take into account the main features and disadvantages of welding joints: uneven strength, uneven heating and cooling processes, as a result, possible warping, residual stress or hidden defects.

Corner connections

Scheme for creating a vertical seam.

In some sources, fillet welds during welding are described as part of T-welds. They are as easy to describe as T-bars: the corner profile resembles the letter “G”, and in GOST 5264-80 they are designated with the initial letter “U”: from U1 to U10.

Despite the apparent simplicity of welding a corner joint, sometimes difficulties arise: metal flows from a corner or vertical surface onto a horizontal one. The solution to this problem is to control the movement of the electrode in order to maintain the correct angles of its inclination, and so that this movement is smooth. In this case, you will receive a high-quality, evenly filled seam.

An excellent way of high-quality corner welding is the method called “boat welding”: the parts are located at right angles to each other, the length of the seams is 8 mm or more.

If corner joints include sheets of metal of different thicknesses - thin and thick - the electrode should be located at an angle of 60 degrees to the thicker part so that more heating occurs on it. Then the thin metal will not burn out.

Welding fillet welds requires compliance with the rules of the geometry of welding joints.

The main geometric criteria are as follows:

• Width - the gap between the edges of the fusion of metals;
• Curvature – the gap at the point of maximum concavity;
• Convexity – the gap at the point of maximum convexity;
• The root of the joint is the edge farthest from the profile (the actual wrong side)

Welding a fillet weld will be most optimal with a concave level shape. This is explained by the risk of incomplete welding of root fillet welds to the full thickness. When it comes to choosing the most durable option possible, there are many different factors to keep in mind.

Main types of welds.

Basic standards of electric welding for the size of the seam:

• Arc voltage;
• Pace of work;
• The size of the wire cross-section;
• Magnitude, density, polarity of voltage.

For example, as the current increases, the penetration depth increases (the size does not change). But at a time when the arc intensifies, the seam expands and, as a result, the depth of penetration decreases.

If the cross-sectional size of the welded wire decreases, the current in the wire increases, the penetration depth increases, and the seam itself decreases in size. There are many examples of the optimal combination of welding factors. All types of welded joints contain the main requirement - not to violate the execution technology, plan in advance and calculate the values ​​of all input parameters.

Overlapping seams

Overlap joints: surfaces are parallel to each other, partially overlap each other, welded in a corner manner. These are the easiest stitches to make - a great start for beginners.

Lap joint - diagram.

All types of overlap welds have a strict limitation on the thickness of the sheet metal - it should be no more than 8 mm. Here it is important to find the correct angle of inclination of the electrode - the range is from 15 to 45 degrees. In GOST, overlap joints are conventionally designated as H1 and H2.

When working with two workpieces, one-sided turned welding is often used, which has a serious drawback: gaps form between the parts. Moisture and corrosion become the main enemies with this method. The result of this type of defect is described in one word - fragility.

However, lap joints have a very wide range of applications, here are a few examples:

• Installation of lightweight structures such as pavilions or stalls;
• Installation of billboards and other structures;
• Assembly of awnings and awnings.

Compare, evaluate

Of the above options, butt welding is considered the most reliable and economical. In terms of current loads, they are almost equal to whole elements that were not welded, in other words, to the base material. Naturally, such strength is achieved only with adequate quality of work.

At the same time, it must be remembered that the reliability and cost-effectiveness of the method does not mean that it is easy to implement. Requirements for edge processing, adjustment of many factors to the conditions of a specific welding, certain restrictions in application due to the shape - all this requires strict professional discipline.

Welding butt seams.

T-joints (including corner ones) are also quite popular. They are especially often used when welding massive structures.

The simplest ones to perform are overlapping joints. They do not require processing, and general preparation is also much simpler. Very popular in welding sheets of small thickness (thickness up to 60 mm is allowed). Simplicity does not mean efficiency: excessive consumption of deposited and base metals is a common situation for such options.

Seams according to position in space

The next classification criterion is the position of surfaces in space. There are four such provisions:

1. Bottom seams
2. Horizontal
3. Vertical
4. Ceiling

If it were possible to choose, experienced craftsmen would choose welding in the lower position. This is the most convenient method, and the weld pool is better controlled. A suitable method for debut works of beginners - there are practically no difficulties here. But the other three spatial options are associated with technical nuances and special requirements for execution.

When welding in a horizontal position, the main problem is gravity - because of it, the metal simply slides down. Such compounds can be cooked both from right to left and from left to right, as is convenient for you. But the rule for using an electrode is the same for everyone: its angle of inclination must be large enough. Of course, when selecting an angle, you need to take into account the current parameters and the speed of movement, everything is interconnected.

Choose, try, the main thing is that the bathtub does not tend to fall down. If the metal still drains, you need to reduce its heating - this can be done by increasing the speed of movement. The second option is to periodically tear off the arc so that the metal cools at least a little. The arc lift method is more suitable for beginners

Classification of seams by position in space.

In vertical connections, the same problem is the force of gravity, but here it is not the entire bath that tends down, but drops of metal. Usually in such cases they take a shorter arc. The seam can be welded in any direction. In the Welding Certification Regulations RD 03-495-02, these options are designated as “welding position B1” - vertical from bottom to top (this method is more convenient). “Welding position B2” is vertical from top to bottom, it is used less often, since strict control of the weld pool is required here.

The ceiling connection is the most difficult in the subgroup, which will require real skill. There are no other options in the position of the electrode - keep it only at a right angle to the ceiling. Make the arc shorter, the speed of the circular motion should be constant. In this case, the release of gases and slags is difficult, and it is difficult to keep the melt from flowing down. Even if the skill is at the proper level, that's all technological requirements executed correctly, the ceiling method is inferior in strength and overall quality welds in all other positions.

Welded joints according to outline

How are they classified? welds by outline:

• Longitudinal: they require the most thorough preparation of the metal in the form of thorough cleaning of burrs, edges and any irregularities; in addition, it is necessary to degrease the surfaces of the welding area.
• Circular: this is work on circles with its own special requirements - extremely high accuracy and precision.

We cook pipelines, special requirements

To work with industrial pipelines Only experienced, certified and highly qualified craftsmen are allowed. Pipe connections belong to the vertical method with all the “vertical” nuances. The peculiarity lies in the angle at which the electrode is held, this is an angle of 45 degrees.

The width of the pipe seam can reach 4 cm, it depends on the thickness of the pipe itself. There are separate standards for this type of welding, for example, GOST 16037-80 describes the dimensions of seams for various connections of pipeline structures.

Cleaning welds

In appearance, newly welded seams sometimes resemble keloid scars on human skin: they are convex and protrude above the surface. Slag, scale, and drops of metal often remain on the surface. All this can and should be removed; the process is called stripping the seams.

Its stages:

• Knock off scale with a hammer or chisel;
• Level the area with a grinder;
• Sometimes it is necessary to apply a thin layer of molten tin (tinning).

Defects and sewing defects

The most common defect in a beginner’s work is a crooked seam with uneven filling. This picture is the result of uneven guidance of the electrode; it literally dances in the hands of the young master. Here you will need perseverance and work: with experience, all this passes without a trace. The second most common mistake is the incorrect choice of current strength or arc length, which leaves “undercuts” or uneven filling. With some defects, aesthetics suffer more, with others - strength.

Lack of penetration - insufficient filling of the joint of parts with metal. It needs to be corrected, since we are talking about the strength of the connection.

In what cases does lack of penetration appear:

• Poor quality processing (or lack thereof) of surface edges;
• The current is too weak;
• Electrode movement too fast.

An undercut is an unnecessary groove along a seam. The diagnosis is simple: choosing an arc that is too long. The treatment is also clear: either a shorter arc, or a higher current intensity.

Examples of electrode movement patterns.

A burn-through is a banal hole in a seam for the following reasons:

• Wide gap between edges;
• The current is too high;
• Low electrode speed

And here we are looking for the optimal ratio of three components: current, gap width, electrode movement.

Pores and nodules are multiple small holes. This is critical, affecting the strength of the connection.

• Dirt and rust on metal;
• Oxygen reaching the molten metal (in a draft);
• Poor quality edge processing;
• Low quality electrodes;
• Use of filler wires;

Cracks are serious violations of the integrity of the seams. They appear after the metal has cooled and are essentially harbingers of the destruction of the seam itself. In this case, only new welding or complete removal of the old seam and re-applying a new one will save.

Is it possible for a beginner to learn how to apply high-quality sutures on his own? Yes, without a doubt. Some sources use the word “with ease.” It’s better not to promise ease, because welding has never been an easy or safe process. But it is quite possible to determine consistent and feasible steps on your own. The principle is from simple to complex. Of course, all the main types of welding joints have their own secrets and subtleties that need to be mastered.

For beginners, electric arc welding is best suited. The best option is to start studying under the supervision of an experienced mentor. But if this is not possible, there are a huge number of videos online showing all the actions and detailed explanations for them.

Single-pass and multi-pass seams.

The main initial stage is the competent preparation of the necessary equipment.

Here's what you need to prepare for electric arc welding:

1. Welding equipment (various types);
2. with the correct diameter (extremely important!)
3. Hammer for cleaning the cooled seam;
4. Metal brush for the same cleaning of the welded area
5. Mask, special light filter.

The requirements for clothing are simple: it must be thick, with long sleeves and gloves. A rectifier with a transformer will come in handy (especially if the equipment is old).

Bottom line

The main types of welded joints are placed within the framework of a precise and clear classification with symbols and a detailed description of technological features and tips. One of the most popular standards is GOST 5264-80, which describes almost all types of welding seams.

You can learn welding on your own according to the principle “from simple to complex.” A “simple” starting point for execution is to take overlapping seams. You can end up working aerobatics– welding for ceiling-mounted surfaces. We wish you pure metal, good orders and a working mood.

Quite often it is necessary to connect metal parts or fragments of parts. There are several ways to get the desired result. Most often, the electric welding method is used to connect iron and steel parts.

What is it based on?

How to cook using electric welding? In order to understand the principle, you need to remember the physics from school curriculum. One of them is connected to the working part. When the electrode comes into contact with this surface, a depression is formed at the point of contact, which is filled with molten metal as the electrode moves. The edges of the metal parts melt under the influence of enormous temperature and turn into a single whole.

Arc ignition methods

When learning how to weld metal using electric welding, it is worth learning something about the method itself. The distance and electrical high-temperature pulse between the workpiece and the electrode is called an arc. There are two ways to create such conditions:

• In the first case, the electrode (by touching quickly) is “struck” on the iron, as if with a match. The resulting arc must be maintained by placing the additive a few mm from the working surface of the metal.
• In the second case, you need to sharply tap the workpiece with the tip of the electrode.

The resulting arc should not go out. If this does happen, before electric welding continues, the seams must be cleaned of scale. Neglecting this rule leads to the formation of a hole.

Importance of Amperage for Welding

Calculating the current strength corresponding to the thickness of the electrode will show in practice how to learn how to weld using electric welding. If the current is insufficient, the electrode will stick and the arc will go out. If the current is high, the metal will spatter and burn. If you use a welding transformer, then a 1 mm electrode corresponds to a current of 30-35 A. When using a 3 mm electrode, a current of 80 A corresponds. If you increase the current, iron can be cut.

Electrodes are selected taking into account chemical composition metal There are several types of this filler material:

• steel;
• bimetallic;
• cast iron;
• copper;
• brass.

All of them are marked with an index and numbers indicating what metal hardness and thickness each type is intended for.

When learning how to properly weld with electric welding, you need to remember that in order to obtain high-quality seams, the electrodes must correspond to the thickness of the metal.

Welding flat metal sheets

Thin metal (from 1 to 3 mm) is joined end-to-end without gaps or additives, achieving good alignment of the aligned edges.

For better fit of joints of thicker sheets (from 3 to 8 mm), the edges should be cut at right angles. A gap of up to 2 mm is left between the sheets. The 8 mm thick material is joined by double-sided welding. To connect thicker planes, the edges are cut with a bevel.

Where to start learning to cook iron

Learning how to properly weld with electric welding begins with the simplest processes.

• The prepared parts are fixed on horizontal surface(on the welding table).
• They are fastened with tacks along the edges and in the center.
• You need to insert a new additive into the holder and attach a ground clamp to the part.
• First, the correct tilt of the electrode (about 75 degrees) in the direction of the arc is practiced. In this case, it is necessary to make movements that, as it were, rake the molten metal to the joint.
• The end of the electrode should be in the center of the seam. Due to the observance of the angle of inclination, the drops flow more evenly from the hot electrode and form an even, high-quality roller
• After the workpiece has cooled, you need to remove the slag from the surface of the part.

Time after time, as you gain experience, the seams will turn out smoother and neater.

How to make a vertical seam

How to weld a vertical seam using electric welding? The main thing is to start, following all the recommendations. Welding vertical seams is similar to working horizontally, only a little more complicated. The workpieces are grabbed in two or three places. Then welding is carried out only from the bottom up, sticking drop by drop. Gradually the entire gap is filled with hot metal. How to learn to cook with electric welding? The task is to merge both edges by melting them with a welding arc, while simultaneously directing drops of metal from the hot liquid end of the electrode into the same area.

You can weld the seam not with drops, but with the so-called “figure eight”, however, only an experienced specialist can handle this. So, if you are interested in knowing how to learn how to weld a vertical seam using electric welding, it is first recommended to look at the work of an experienced welder and listen to the advice of the masters. And only then start the process yourself.

How to make a beautiful and strong corner seam

Making a so-called “T” seam correctly is not as easy as learning how to weld using electric welding. This seam is used if you need to fasten parts at different angles. The metal parts are installed so that the welding flows into the very corner. The parts to be welded, fixed with a “boat,” are grabbed from opposite sides. In addition, one edge of the workpiece is raised a little higher. The welding process must begin from the bottom edge. In this case, by carefully following the instructions on how to properly weld with electric welding, the quality of the weld can be significantly improved.

Which one is better to use?

1. The old ones, which have an adjustable magnetic gap that allows you to adjust the current strength, are transformer ones. There are many options and models that have rheostats and additional chokes on the primary or secondary sides of the transformers.
2. Inverter machines are more modern welding devices. Operating at a higher frequency, the transformer of such units has smaller dimensions and light weight. In such devices you can smoothly adjust the welding modes. The latter must be configured carefully, otherwise the device may quickly fail.

Pipe welding methods

If you have no experience, it is better to learn how to weld a pipe by electric welding on thick metal. Depending on the thickness of the pipe wall, several passes are made. Multilayer welding improves the mechanical properties of the resulting seam, and the connection becomes stronger.

First, weld the half ring in one direction, then in the other. When making a seam “from top to bottom”, 4 mm electrodes with organic coating are used. With a short arc, relying on the resulting “visor”, the attachments are driven with small transverse vibrations.

When working using the “bottom-up” method, the speed is sharply reduced. Transverse vibrations of the electrode are carried out at 3-5 mm.

When using pipes, you must first prepare and lay out all the material on a welding table or stand. They are then centered and pulled together to obtain the required gap for welding. The assembled joints are clamped together.

Pipes with a small diameter are connected by continuous welding, and those with a large diameter - intermittently. After completing all welding processes, the working surface of the metal is cleaned of scale, frozen splashes, and slag. A control inspection is carried out to detect cracks or burns, craters or pores. If there are poorly welded areas, the seam is restored.

For your own safety, you need to work while welding in suede gloves and mittens, in a welder’s mask, in tarpaulin or thick leather boots and in a cotton robe. Be sure to have a fire extinguisher or a container of water nearby.

Answer:

This question is quite complex and the answer needs to be given in detail. There are three types of welds - vertical, horizontal and overhead. The first is considered the simplest, the last - the most difficult. Each has its own welding technology.

Vertical seam weld

This type of weld can be performed in two ways - downhill and uphill. Uphill welding is easier to perform, since less effort has to be applied to prevent the metal from flowing down, since it will be held by the already slightly hardened metal in the weld pool remaining behind the electrode. The seam will be less neat and beautiful than when welding downhill, but for beginners this is not so important.

If you want to get an even and neat seam, then try welding downhill. This method is more labor-intensive, since you have to carefully weld the place where the parts are fastened and constantly ensure that the molten metal does not leak down. The optimal angle for vertical welding is 45 degrees.

Horizontal welding seam

This is a rather difficult weld to make; during welding, metal can flow down to the lower edge. To prevent this, it is advisable to make a bevel on the top edge. And leave the bottom one unchanged, then it will act as a limiter for the molten metal.

When welding a horizontal seam, the electrode must be held at an angle of about eighty degrees, almost perpendicular to the surface to be welded. You need to walk the electrode several times. During the first pass, you should thoroughly boil the root bead, which is done without transverse movements with a short arc.

The second roller is created in one pass at an average current using an electrode of a larger diameter. Next, evaluate the distance between the top edge and the second roller. If it is wide enough to accommodate two more weld beads, then make a third and fourth pass. The main task is to smooth out the depression between the last roller and the top edge.

Ceiling welding seam

This weld is difficult because it involves a huge risk of metal leaking and droplets from the upside-down weld pool. To prevent this from happening, it is necessary to use thin electrodes (no more than four millimeters in diameter) and a reduced current strength, and also periodically remove the electrode from the weld pool so that the molten metal has time to solidify in time. It is usually recommended to weld ceiling seams at an angle of approximately 75 degrees using forward movements with the electrode returning or forming a zigzag line. This allows you to keep the molten metal in the weld pool, moving the electrode away from it in time. When welding ceiling seams, it is especially important to take maximum measures to protect the welder’s skin and eyes from metal drops. When making such a seam, it is better to cover all parts of the body as much as possible, including ears, neck, and hair.

The easiest way to make welds is with equipment that allows you to smoothly regulate the current. Such equipment includes inverter welding machines. In our online store you will find household, professional and semi-professional inverters. Among the first we can recommend