Welding For Dummies

Every critical welding technique and process distilled into a one-stop, accessible resource 

Safe and effective welding might seem like a pipe dream if you’re just getting started. But with a little help from Welding For Dummies you’ll be a “golden arm” in no time. This guide will give you techniques you need to get a handle on material evaluation, clean-up, and every step in between. 

You’ll find practical advice on every popular kind of welding, including stick, tig, mig, fluxcore, and even oxyfuel cutting. You’ll also get tips on the ideal welding techniques to choose for specific projects. The book shows you how to: 

• Find the required training for welding certifications 
• Use brand-new welding technologies, including laser techniques 
• Practice critical welding techniques you can use in your own hobby shop while staying safe 

Whether you’re looking for some help to further your do-it-yourself projects at home or you’re just getting started with a traditional welding educational program and you need a useful supplementary resource, Welding For Dummies is an irreplaceable reference that helps make a challenging trade accessible to everyone. 

Steven Robert Farnsworth, is a certified welding inspector and instructor with over 20 years of experience teaching all methods of welding. He previously served as a welder in the United States Navy.

Introduction 1

About This Book 1

Conventions Used in This Book 2

What You’re Not to Read 2

Foolish Assumptions 3

How This Book Is Organized 3

Part 1: Understanding Welding Basics 3

Part 2: Welding on a Budget: Stick and Tig Welding 4

Part 3: Discovering Mig Welding 4

Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes 4

Part 5: Putting Welding into Action with Projects and Repairs 4

Part 6: The Part of Tens 5

Icons Used in This Book 5

Where to Go from Here 5

Part 1: Understanding Welding Basics 7

Chapter 1: Diving Into the World of Welding 9

If You Can’t Beat ’Em, Join ’Em: Understanding Why Welding Matters 10

Fabricating metal products 10

Repairing metal pieces or products 11

Getting Familiar with Metals 12

Steel 13

Stainless steel 13

Aluminum 14

Taking the Time to Understand Welding Safety 14

Exploring Welding Methods 15

Stick welding 15

Mig welding 16

Tig welding 17

Other welding methods 18

Looking at the Future of Welding 18

Chapter 2: Considering Commonly Welded Metals 19

Steeling Yourself for Using Steel 20

Getting a handle on forms of steel 20

Knowing when steel is appropriate 21

Preparing steel for welding 23

Exploring steel welding methods 26

Going with Stainless Steel 27

Understanding the differences between steel and stainless steel 27

Deciding when to use stainless steel 27

Looking at stainless steel welding methods 28

Working with Aluminum 29

Perusing the properties of aluminum 29

Eyeing aluminum welding techniques 30

Considering Other Metals 30

Chapter 3: Setting Your Sights on Welding Safety 33

Gearing Up to Protect Yourself 34

Choosing eye protection 34

Keeping the right fire extinguisher on hand 36

Wearing protective clothing 38

Watching health hazards: Using a respirator and Material Safety Data Sheets 39

Observing Basic Safety Rules 40

Keeping your work space clean 41

Checking for leaks 42

Getting the ventilation right 42

Storing flammable liquids and gases 43

Knowing your surroundings 44

Protecting yourself from electric shock 45

Shielding yourself from burns 46

Maintaining your equipment 47

Being Prepared for Injuries and Accidents 48

Equipping your first-aid kit 48

Knowing how to handle injuries 49

Chapter 4: Setting Up Your Welding Shop 53

Choosing a Location 54

Deciding how much space you need 54

Contemplating indoor versus outdoor 55

Equipping Your Welding Shop 56

Making sure you have the basic hand tools 58

Choosing a welding table 60

Selecting your welding machine 61

Considering a few accessories for your welding shop 67

Part 2: Welding on a Budget: Stick and Tig Welding 71

Chapter 5: Getting on the Stick: Understanding Stick Welding 73

Looking at the Pros and Cons of Stick Welding 74

Understanding the Factors That Influence Stick Welding 75

Getting Familiar with Stick Welding Equipment 76

Discovering the differences among stick welding machines 76

Setting up your stick welding machine 80

Nailing down the basics of stick welding’s electrodes 80

Choosing tools and supplies every stick welder needs 81

Chapter 6: Getting to Work with Stick Welding 85

Preparing to Stick Weld 86

Setting up your work area 86

Understanding stick welding electrodes 87

Setting the Machine 90

Choosing polarity 91

Setting the amperage 91

Preparing to weld 92

Striking and Maintaining an Arc 93

Assume the Position: Stick Welding in All Positions 95

Welding on a flat surface 96

Going vertical 97

Exploring horizontal welding 101

Reaching overhead 102

Chapter 7: To Tig or Not To Tig: Understanding Tig Welding 105

Taking a Closer Look at Tig Welding Components 106

Considering the Advantages and Disadvantages of Tig Welding 107

Brushing Up on Tig Welding Basics 108

Showing your metal: Looking at a few metals for tig welding 108

Taking steps to ensure quality welds 109

Stocking the Shop: Examining Tig Welding Equipment 110

Considering fully equipped tig machines 112

Thinking about tig torches 113

Selecting and managing shielding gas 113

Controlling current and amperage 116

Selecting filler metal 117

Exploring tungsten electrodes 118

Chapter 8: Trying Out Tig Welding 119

Getting Your Welding Setup Tig-ether 119

Taking care of tungsten electrode details 120

Making sure your shielding gas is set up correctly 122

Figuring out your tig filler rods 122

Matching Materials and Settings 123

Getting a Handle on Using Your Tig Torch 125

Choosing an electrical current and striking the arc 125

Get a grip: Holding your tig torch correctly 127

Giving Tig Welding a Try 127

Tackling the first weld 128

Trying a butt joint 129

Welding a lap joint 130

Making a T joint 131

Part 3: Discovering Mig Welding 133

Chapter 9: Understanding the ABCs of Mig Welding 135

Understanding How Mig Welding Works 136

Considering Mig Welding’s Advantages and Limitations 138

Bringing Out the Big Guns (And Other Mig Welding Equipment) 140

Mig welding machines 140

Mig welding guns 141

Electrode wire feeders 141

Sifting Through Shielding Gases for Mig Welding 142

Taking a Look at Electrode Wire 144

Adjusting Mig Equipment to Suit Your Mig Welding Project 147

Chapter 10: Practicing Mig Welding 149

Preparing to Mig Weld 149

Getting the equipment ready 150

Setting the wire feed speed and voltage 152

Settings for flux-cored arc welding 153

Settings for aluminum MIG welding 154

Trying Out Mig Welding 155

Making vertical mig welds 158

Joining pieces of sheet metal 159

Watching Out for Common Mig Welding Defects 160

Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes 161

Chapter 11: Examining Plasma and Oxyfuel Cutting 163

Understanding Plasma Arc Cutting 163

Identifying some good materials for plasma cutting 164

Taking a look at plasma cutting’s advantages and disadvantages 165

Perusing and Preparing Plasma Arc Cutting Equipment 166

Getting a handle on plasma cutting equipment 166

Setting the equipment up properly 168

Exploring Oxyfuel Cutting Basics 169

Considering what you can (and can’t) cut with oxyfuel 169

Looking at the pros and cons of oxyfuel cutting 170

Checking Out and Setting Up Oxyfuel Cutting Equipment 170

Examining oxyfuel cutting equipment 171

Deciding among different gas cylinder sizes 174

Setting up oxyfuel cutting equipment 174

Chapter 12: Ready, Set, Cut! Trying Out Plasma Arc Cutting and Oxyfuel Cutting 177

Exploring Plasma Arc Cutting 178

Slicing a straight line 179

Cutting a circle 180

Creating a bevel 181

Practicing Oxyfuel Cutting 182

Lighting the torch 183

Making a straight cut 185

Cutting out a circle 186

Taking on a beveled edge 187

Chapter 13: Exploring Special Weld Processes 189

Working Through the Basics of Welding with Gas 189

Taking a gander at gas cylinders 190

Looking at more gas welding equipment 191

Getting to work with gas welding 193

Discovering Brazing (Braze Welding) 197

Keeping a few brazing rules in mind 197

Giving brazing a try 198

Finding Out about Fusion Welding 200

Soldering On: Exploring Soldering 201

Following the rules of soldering 202

Understanding the two types of soldering 204

Trying the soldering process 204

Chapter 14: Exploring Pipe Welding 207

Delving into the Different Kinds of Pipe 208

Getting Down to Welding Steel Pipes 208

Getting set up and preparing the pipe 209

Making the tacks 211

Welding the pipes 213

Trying some other angles 214

Peeking at a Few More Types of Pipe Welding Joints 216

Keeping an Eye Out for Common Pipe Welding Defects 217

Chapter 15: Working with Cast Iron 219

Casting Light on the Three Most Common Types of Cast Iron 219

Gray cast iron 220

Malleable cast iron 220

Nodular cast iron 221

Getting the (Cast) Iron in the Fire: Welding Gray Cast Iron 223

Stick welding cast iron 223

Oxyfuel welding cast iron 226

Mig welding cast iron 228

Part 5: Putting Welding into Action with Projects and Repairs 231

Chapter 16: Two Welding Projects to Boost Your Welding Shop 233

Creating a Torch Cart 233

Gathering the materials 235

Acquiring the right steel pieces 235

Measuring and cutting pieces 237

Making the welds 238

Adding the wheels 242

Checking your welds 243

Picking out your paint 244

Fabricating Your Own Portable Welding Table 244

Rounding up your tools 245

Picking out the parts 246

Assembling the pieces 246

Ensuring smooth edges 249

Choosing your paint 250

Putting on the wheels 250

Chapter 17: Constructing a Campfire Grill 251

Fabricating a Campfire Grill 251

Getting your tools in order 252

Obtaining the proper steel pieces 253

Cutting the steel pieces to length 255

Welding the grill 256

Picking out your paint 258

Seasoning the cooking surface 259

Chapter 18: Fixin’ to Fix Things: Analyzing and Planning 261

Determining Whether Something Is Fixable 262

Planning a Repair Strategy 263

Identifying the metal and what it means for the repair 264

Deciding which welding process to use for your repair 267

Making and following your plan 268

Getting Ready to Make Repair Welds 269

Preparing your repair piece and work area 270

Gathering your equipment and tools 271

Selecting filler rods and electrodes 271

Considering Cracks 273

Part 6: The Part of Tens 275

Chapter 19: Ten Tools Every Welder Wants 277

4½-Inch Grinder 278

Hacksaw 278

Air Compressor 278

⅜-Inch Electric Drill 279

Wrench Set 280

Steel Sawhorses 281

Cutoff Saw 281

Bench Grinder 283

Bottle Jack 284

Toolbox 284

Chapter 20: (Not Quite) Ten Advantages of Being a Certified Welder 287

More Job Opportunities 288

Better Pay 289

More Chances for Advancement 289

Certification that Travels with You 290

Ability to Join a National Organization 290

Qualification in Specific Areas of Welding 291

Increased Confidence in Your Welding Skills 291

Listing in the American Welding Society Database 292

A Head Start on Additional Types of Welding Certification 292

Chapter 21: (Almost) Ten Welding Defects 293

Incomplete Penetration 294

Incomplete Fusion 295

Undercutting 296

Slag Inclusions 296

Flux Inclusions 297

Porosity 298

Cracks 299

Warpage 300

Spatter 301

Chapter 22: Ten Signs You’re Welding Correctly 303

The Weld Is Distributed Equally between Parts 304

The Slag or Shielding Material Doesn’t Stick to the Weld 304

No Holes or Irregularities on the Weld Surface 305

The Weld Is Tight 305

The Weld Is Leakproof 305

The Weld Has Full Penetration 306

The Weld Has No Undercutting 306

The Weld Has No Overlap 307

The Weld Meets Strength Requirements 307

You’re Safe and Healthy 308

Chapter 23: Ten Maintenance Tips for Your Welding Equipment and Shop 309

Checking on Your Hand Tools 309

Taking Care of Power Tools 311

Doing Basic Housekeeping in the Shop 312

Protecting Your Welding Helmet 312

Seeing to Stick Welding Machine Maintenance 313

Working on Maintaining Your Mig Welding Machine 314

Tuning Up Your Tig Welding Machine 316

Taking Care of Your Oxyfuel Equipment 317

Keeping Your Air Compressor Working 318

Drill Press Maintenance 318

Glossary 321

Index 341

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