Tools/mig/induction

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

MIG Welder induction - Level 1

Level 1 induction in intended to cover the basics of how to use the MIG welder. It should cover basic safety information and how to use the welder effectively on mild steel in positions 1G and 2G/F

Topic	Detailed contents	Rationale
Types of welding available	MMA - Fast, thick, dirty, good outdoors, medium-high skilled MIG - Fast, medium thickness, relatively clean, low-skill requirement TIG - Slow, Neat, special materials, super-clean, high-skilled Forge - V.V.Slow, good for big flat welds, high-skilled Spot - Tiny spot welds for joining plate, low-skilled	Which technique to use for which weld
Machine Description	Parts Base unit Power source Wire feed mechanism Torch Shroud Tip Trigger Gas bottle Types of gas and why Regulator Basic gas bottle safety Earth Clamp Controls Gas Flow Wire Feed Power Don't worry about timer mode, it's not very useful and just make sure it's turned off Wire type, liner and torch can be changed, but not covered at induction level-1	Covering what all the parts are called and which control does what
How it works	Machine strikes arc, melting a pool of metal Wire dips in and out, adding metal to the pool Gas shields the hot metal from the air Earth clamp provides return path	Basic process details
Safety	Fire hazard Metal sparks and radiant heat/light Clear area of flammable materials, be aware of solvents and vapours Having fire extinguishers handy and what types are suitable Arc-eye hazard to you and people around you Using an auto-darkening welding mask Suitable settings on mask (9-11, 12 maybe - start at 10 and adjust) Shouting "Eyes" PPE - Overalls, stout shoes, gloves, mask, dust protection when needed, Cover all exposed skin or you'll regret it! Care with Galvanised steel, risk of metal-fume-fever Gas safety Enclosed spaces Low spaces Fumes	Using the equipment without harming self or others
Preparing to weld	Check metals are suitable Mild steel only Beware of galvanised steel General angle grinder safety Types of disc Changing the disc Care of position and cut angle Dust protection, eye protection, gloves DO NOT TWIST in a cut Clean up weld area - be aware of burning paint Clean area for earth clamp Bevelling edges to form a path for the bead on butt joints No bevel on thin materials Regular 2/3rds bevel most of the time Bevelling from both sides for very thick	Proper preparation is necessary for good welds, cover bevel patterns for other weld types later
How to actually execute a weld	Proper position of self and torch, direction of motion Push welding - Normal, safe option Pull welding - bigger bead, better penetration, lots of grind and risk of inclusion Vertical and overhead welds Correct distance How the pool forms Dip transfer, globular transfer, spray transfer Taking the pool "for a walk" Moving patterns, circles, arc, steady Proper sound "Frying Bacon" [Demonstrate a good simple weld bead]	Cover the basic technique of establishing and moving a weld bead
Problems	[Deliberately set up and demonstrate each of these faults] Erratic weld, globular transfer - too little wire feed Stabbing and poor penetration - too much wire feed Bead sitting on surface - too fast or too little power Weld flat and spattered - too much power over-penetration - too slow or too much power blowing holes in material - MUCH too much power Lots of sparks and brown/porous weld - not enough gas or too far away Weld moves around erratically - too much gas or influence from holding magnets Weld sticks to tip - too close	Recognising faults and knowing how to fix them
Example	Example	Example
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Getting a nice steady bead on flat material

Butt joint Proper grinding and prep Bevels right way up and properly spaced Option of using backing blocks using holding magnets and clamps Do NOT tack work to the table Tacking - you are GOING to get distortion Root-weld and multi-pass welding on thick material straight, back-tack and half-split tack welding

Lap joint Proper grinding and prep

T-joint Proper grinding and prep

Pool welds

MIG Welder induction - Level 2

Level 2 induction should cover more advanced uses

• Welding mild steel in position 3
• Changing wire, torches and liners, proper setting of wire feed and tension
• Welding with Aluminium and Stainless Steel