Tools/TIG/induction: Difference between revisions
imported>Stever (→TIG welder induction (TIG Mode) Level 1: First go at a full induction script for TIG) |
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* Fire hazard |
* Fire hazard |
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** Metal sparks and radiant heat/light |
** Metal sparks and radiant heat/light |
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** Clear area of flammable materials, be aware of solvents and |
** Clear area of flammable materials, be aware of solvents and vapors |
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** Having fire extinguishers handy and what types are suitable |
** Having fire extinguishers handy and what types are suitable |
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* Arc-eye hazard to you and people around you |
* Arc-eye hazard to you and people around you |
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** Shouting "Eyes" |
** Shouting "Eyes" |
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* PPE - Overalls, stout shoes, gloves, mask, dust protection when needed, Cover all exposed skin or you'll regret it! |
* PPE - Overalls, stout shoes, gloves, mask, dust protection when needed, Cover all exposed skin or you'll regret it! |
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* Care with |
* Care with Galvanized steel, risk of metal-fume-fever |
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*Gas safety |
*Gas safety |
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** Enclosed spaces |
** Enclosed spaces |
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** Mild/Stainless steel only at level-1 induction |
** Mild/Stainless steel only at level-1 induction |
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*** At level-2 aluminium and other metals are covered, TIG can weld almost anything metallic and some things that arn't |
*** At level-2 aluminium and other metals are covered, TIG can weld almost anything metallic and some things that arn't |
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** Beware of |
** Beware of galvanized steel |
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** Beware of lead-bearing and copper-bearing paints |
** Beware of lead-bearing and copper-bearing paints |
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* General angle grinder safety |
* General angle grinder safety |
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* Clean up weld area - be aware of burning paint |
* Clean up weld area - be aware of burning paint |
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* Clean area for earth clamp |
* Clean area for earth clamp |
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* Beveling edges to form a path for the bead on butt joints |
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** No bevel on thin materials |
** No bevel on thin materials |
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** Regular 2/3rds bevel most of the time |
** Regular 2/3rds bevel most of the time |
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** |
** Beveling from both sides for very thick |
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* Fire hazard |
* Fire hazard |
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** Largely as for MIG/MMA |
** Largely as for MIG/MMA |
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** Clear area of flammable materials, be aware of solvents and |
** Clear area of flammable materials, be aware of solvents and vapors, especially as solvent cleaning is commonly used for TIG |
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** Having fire extinguishers handy and what types are suitable, TIG uses a higher voltage so avoid water type |
** Having fire extinguishers handy and what types are suitable, TIG uses a higher voltage so avoid water type |
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* UV Hazard |
* UV Hazard |
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** Mild/Stainless steel only at level-1 induction |
** Mild/Stainless steel only at level-1 induction |
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*** At level-2 aluminium and other metals are covered, TIG can weld almost anything metallic and some things that arn't |
*** At level-2 aluminium and other metals are covered, TIG can weld almost anything metallic and some things that arn't |
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** Beware of |
** Beware of galvanized steel, it's even worse for TIG than MIG |
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** Beware of lead-bearing and copper-bearing paints |
** Beware of lead-bearing and copper-bearing paints |
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* Cleaning must be immaculate, much better than for MIG as TIG gas provides no fluxing action at all |
* Cleaning must be immaculate, much better than for MIG as TIG gas provides no fluxing action at all |
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** Clean up weld area - be aware of burning paint |
** Clean up weld area - be aware of burning paint |
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** Clean area for earth clamp |
** Clean area for earth clamp |
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** |
** Beveling joints is same as for MIG/MMA |
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** Power and overheat lights - Duty cycle, 100%@90A, 60%@115A, 20%@200A but max is about 120A on 13A plug |
** Power and overheat lights - Duty cycle, 100%@90A, 60%@115A, 20%@200A but max is about 120A on 13A plug |
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** Process |
** Process |
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*** Lift-TIG - Hard to use, not covered at level-1, only useful if |
*** Lift-TIG - Hard to use, not covered at level-1, only useful if sensitive electronics are nearby |
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*** HF-TIG - Standard mode, use this |
*** HF-TIG - Standard mode, use this |
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*** Stick - See TIG Welder (Stick mode) Induction, beware that going into stick mode - even momentarily - will cause the electrode to become live at up to 90V with no control from the trigger |
*** Stick - See TIG Welder (Stick mode) Induction, beware that going into stick mode - even momentarily - will cause the electrode to become live at up to 90V with no control from the trigger |
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| PPE safety || |
| PPE safety || |
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* Overalls are required for UV protection |
* Overalls are required for UV protection |
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* We have special TIG gloves that are |
* We have special TIG gloves that are much lighter and less stiff than normal welding gloves which can be used because TIG doesn't generate very much radiant heat or spatter. These gloves are specifically reserved for TIG welding and must not be used for anything else |
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* Depending on the welding current you may want to use shade 9-12 on the welding helmet. All settings will save your vision, you're just adjusting for best visibility. If you're used to MIG/MMA then go one setting darker than you normally would for this current |
* Depending on the welding current you may want to use shade 9-12 on the welding helmet. All settings will save your vision, you're just adjusting for best visibility. If you're used to MIG/MMA then go one setting darker than you normally would for this current |
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* You may see people online welding without overalls or even without gloves. They can get away with this because of the low-spatter nature of TIG welding. DO NOT DO THIS - They are probably wearing SPF-1000 sunblock and have developed a tolerance over years, they'll still probably wind up getting skin cancer from it! Cover all exposed skin at all times while welding. |
* You may see people online welding without overalls or even without gloves. They can get away with this because of the low-spatter nature of TIG welding. DO NOT DO THIS - They are probably wearing SPF-1000 sunblock and have developed a tolerance over years, they'll still probably wind up getting skin cancer from it! Cover all exposed skin at all times while welding. |
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| Arc too long || Puddle is slow forming, arc sounds/looks like a flame, heat zone very large || Having the arc too far away is causing the voltage to go too high and meaning the heat is spread over too wide an area |
| Arc too long || Puddle is slow forming, arc sounds/looks like a flame, heat zone very large || Having the arc too far away is causing the voltage to go too high and meaning the heat is spread over too wide an area |
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| Arc too short || Puddle is tiny, pool rises up to touch electrode || Having the arc too short focuses the heat onto too small an area which will make it hard to join workpeices, the short arc causes the pool to move towards the electrode. |
| Arc too short || Puddle is tiny, pool rises up to touch electrode || Having the arc too short focuses the heat onto too small an area which will make it hard to join workpeices, the short arc causes the pool to actually dome upwards and move towards the electrode. |
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| Angle too steep || Large flame-like arc, elongated puddle, difficulty controlling filler rod || The steep angle causes the arc to spread out sideways and fail to remain directly under the point of the electrode, the heat spreads too far down-weld of the torch changing the puddle shape and the plasma jet tends to melt filler rods before they can get to the pool. |
| Angle too steep || Large flame-like arc, elongated puddle, difficulty controlling filler rod || The steep angle causes the arc to spread out sideways and fail to remain directly under the point of the electrode, the heat spreads too far down-weld of the torch changing the puddle shape and the plasma jet tends to melt filler rods before they can get to the pool. |
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| Lap joint || |
| Lap joint || |
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* Lack of need for grinding but must still be cleaned |
* Lack of need for grinding but must still be cleaned |
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* Treat |
* Treat it as two fillet joints |
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** But watch out for heat buildup in the edges |
** But watch out for heat buildup in the edges and undercutting |
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** Extra care if the sheet is thin to watch for balling up |
** Extra care if the sheet is thin to watch for balling up |
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* Alternating stitch welds to control distortion |
* Alternating stitch welds to control distortion |
Revision as of 14:53, 4 December 2018
Some of the tools at the Hackspace are potentially hazardous to use, for these tools members are required to have an induction before they can use them. Inductions provide the most basic information on how to safely and effectively use the simpler functions of the tools, we appreciate that some members may have professional experience on some of these tools and in this case please tell your induction provider and the induction may be very reduced and just cover any risks or procedures specific to rLab. Some tools have multiple levels of induction in order to cover more advanced uses of that tool without making the basic induction take too long, higher induction levels will introduce some of the more advanced features of the tools but as with all inductions are only intended to provide basic information on the capabilities of the tools and how to use them safely. Some members of rLab may be willing to offer more detailed tuition beyond basic induction level or offer guided practice sessions in exchange for beer money or assistance on their own projects.
For all tools you are only required to take level-1 induction before use, after that you may perform any task that you feel confident you can do safely, higher levels of induction may be useful to you in performing more advanced operations but are not required before doing tasks covered in them so long as you're confident of your ability to handle those tasks without risk to yourself, others, or the tool.
PLEASE NOTE : All induction providers are volunteers who are providing inductions to the best of their ability but are NOT qualified instructors. Inductions are provided on a best-effort basis but you and you alone are responsible for your safety while using the tools and for satisfying yourself that you can operate the tools safely. There are professional training courses available from various providers in Reading and the surrounding area if you feel they are appropriate for the level of work you intend to undertake. Reading these notes is NOT a substitute for an in-person induction.
Note for wiki editors : Please do not edit induction pages unless you are one of of the people that gives that induction
TIG welder induction (TIG Mode) Level 1
Level 1 induction in intended to cover the basics of how to use the TIG welder, it covers basic safety information and how to use the welder effectively on mild and stainless steel in positions 1G and 2G/F. It is strongly recommended that people undertake MIG induction and practice it thoroughly before attempting TIG welding, that said you can start welding straight away with TIG but it's likely to take considerably longer to develop the required skill to use it effectively. People undertaking TIG induction need to have overalls or other non-flammable clothing that covers all exposed skin except for head and hands. Wear stout shoes or boots, no open shoes allowed. If you have any metal you'd like to practice on then please bring it with you so long as it's plain steel with no galvanized coating or paint but if you don't have any then we usually have suitable scrap around to practice on. There's no charge specifically for the induction but normal welder usage charges apply, you should expect it to cost around £5 for the induction and a bit more if you spend some time practicing afterwards which is strongly recommended. This induction is estimated to take 2 hours. Please remember that what you might have seen on youtube/instagram is people showing off their very best welds that may have taken years of practice and multiple attempts to achieve, you will NOT be getting results like that after just an induction. The goal for induction is to be able to use the TIG welding without being a danger to yourself or others, it's not even to achieve structurally sound welds, TIG welding is a high-skilled process and it takes a minimum of hundreds of hours of practice to get photograph-worthy results like that.
For people who've not welded before | For people who can already MIG weld | ||||||||||||||
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For people who've not welded before the full technique and safety briefing is required
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For people who can already MIG/MMA weld this can be shorter
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Topic | Detailed contents | Rationale | ||||||||||||||||||||||||||||||
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How it works |
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Basic process details | ||||||||||||||||||||||||||||||
Machine Description |
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Covering what all the parts are called and do | ||||||||||||||||||||||||||||||
Preparing to weld (continued) |
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Proper preparation is necessary for good welds | ||||||||||||||||||||||||||||||
Setting up the welder |
Start at the tip of the torch and work back....
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Suitable setup and settings for executing the weld | ||||||||||||||||||||||||||||||
Configuring the welder |
Welder Settings
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How to set the arc parameters | ||||||||||||||||||||||||||||||
PPE safety |
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Using the right PPE for TIG welding | ||||||||||||||||||||||||||||||
How to actually execute a weld |
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Cover the basic technique of establishing and moving a weld bead | ||||||||||||||||||||||||||||||
Problems |
These are some of the problems you might find when welding [Deliberately set up and demonstrate each of these faults]
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Recognizing faults and knowing how to fix them | ||||||||||||||||||||||||||||||
Practicing a steady bead | Inductee practices moving the puddle on flat stock till competent (may take a lot of time and re-grinding) | Getting the basics right | ||||||||||||||||||||||||||||||
Laying a bead using filler |
[Demonstrate laying a bead along a bit of thick material] [Demonstrate too little and too much filler] [Inductee practices laying a filler bead] |
Laying a bead while using filler | ||||||||||||||||||||||||||||||
Butt joints |
[Demonstration and practice till successful] |
Executing the most basic weld | ||||||||||||||||||||||||||||||
Fillet joints |
[Demonstration and practice till successful] |
Second most common weld type | ||||||||||||||||||||||||||||||
Lap joint |
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Next joint type | ||||||||||||||||||||||||||||||
Shutting down and cleaning up |
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Clean up after yourself and pay what you owe! | ||||||||||||||||||||||||||||||
Final thoughts |
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Closing comments |
TIG welder induction (TIG Mode) Level 2
Level 2 TIG induction is intended to allow people to convert from working on steel to working on aluminium and other alloys and to further develop the skills required for more challenging welding applications such as position 3&4 welds and welding aluminium, magnesium, silicon alloys and TIG brazing. There is a charge of £20 to cover materials and machine charges for Level-2 induction, at least a week's notice is required in order to get the necessary materials and the induction is anticipated to take 2-3 hours.
TIG welder induction (MMA mode)
This induction in intended to cover the basics of how to use the TIG welder in MMA (stick welding) mode, it covers basic safety information and how to use the welder effectively on mild steel in positions 1G and 2G/F. It is strongly recommended that people undertake MIG induction and practice it thoroughly before attempting stick welding, that said you can start welding straight away with stick but it's likely to take considerably longer to develop the required skill to use it effectively. People undertaking stick welding induction need to have overalls or other non-flammable clothing that covers all exposed skin except for head and hands. Wear stout shoes or boots, no open shoes allowed. If you have any metal you'd like to practice on then please bring it with you so long as it's plain steel with no galvanized coating or paint but if you don't have any then we usually have suitable scrap around to practice on. There is a charge of £10 for the induction to cover materials and a bit more if you spend some time practicing afterwards which is strongly recommended. The needed materials are usually kept in stock but if we've run out it will take several days to get more. This induction is estimated to take 1-2 hours.