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Welding and Cutting

The welding and cutting category covers the various types of welding (arc, mig, tig) and the carious electrodes used for welding various metals. There are also questions regarding tips on various problems experienced by welders. Cutting is also a part of a welder's job and it too has many aspects.

500 Questions

Why is ethane and air mixture not used for welding?

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When ethyne is burnt in air, it gives a sooty flame. This is due to incomplete combustion caused by limited supply of air. However, if ethyne is burnt with oxygen, it gives a clean flame with temperature 3000°C because of complete combustion. This oxy-acetylene flame is used for welding. It is not possible to attain such a high temperature without mixing oxygen. This is the reason why a mixture of ethyne and air is not used.

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Mineral based fluxes welding?

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Mineral-based fluxes are commonly used in welding to facilitate the joining of metals by removing oxides and impurities from the surfaces, promoting wetting, and preventing oxidation during the welding process. These fluxes are composed of mineral compounds such as borax, fluoride, and chloride, which lower the melting point of the oxide layers and help to create a clean and strong weld. Different types of mineral-based fluxes are used based on the specific requirements of the welding application, such as soldering, brazing, or welding different metals.

Is propylene used in welding?

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Yes, propylene can be used as a fuel gas in welding applications. It is commonly used as an alternative to acetylene because it produces a similar flame temperature and is easier to handle and store. It is often used in cutting and brazing processes.

What size wire for a welding extension cord 220v 50 amps?

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For a 220V 50A welder, you would need a minimum of 6-gauge wire for your extension cord to ensure it can handle the current safely. It's recommended to use a heavy-duty, outdoor-rated extension cord with appropriate wire gauge and length to avoid voltage drop and overheating.

Why solder wire is used for welding electrical wire?

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Solder wire is used to join electrical wires together by creating a strong and conductive bond. The solder melts at a lower temperature than the wires, allowing it to flow and form a connection when heated. This creates a secure joint that helps maintain electrical conductivity and prevents the wires from coming apart.

How is carbon monoxide created during welding?

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Carbon monoxide can be created during welding when the heat from the welding process causes carbon-containing compounds, such as paint or lubricants, to break down and release carbon monoxide gas. It can also be produced when the shielding gas used in welding (like carbon dioxide) reacts with the metal being welded at high temperatures. Proper ventilation and using appropriate welding techniques can help minimize the production of carbon monoxide during welding.

What reaction takes place during oxyacetylene gas welding?

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During oxyacetylene gas welding, acetylene gas and oxygen are mixed in a torch and ignited to produce a high-temperature flame. The heat from this flame melts the metal being welded, while the oxygen assists in the combustion process by providing additional heat and reacting with the metal to form an oxide layer that is then removed as slag.

Which alkyne combusts with pure oxygen to release intense energy as heat in welding torches?

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Acetylene is the alkyne that combusts with pure oxygen to release intense energy as heat in welding torches. It produces a very high flame temperature, making it suitable for welding and cutting metals.

What is brighter the sun or welding?

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The sun is brighter than welding. The sun's surface temperature reaches about 5,500 degrees Celsius, while welding temperatures can range from 1,500 to 3,000 degrees Celsius.

How far away from welding or cutting operation must you keep combustible materials?

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A safe distance of at least 35 feet should be maintained between welding or cutting operations and combustible materials, or appropriate flame-resistant barriers should be used. It is essential to prevent sparks, slag, or heat from igniting nearby flammable substances, which could lead to fires or explosions. Regularly inspect and remove any flammable materials within the designated area to ensure a safe work environment.

What is lack of fusion in welding?

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Lack of fusion in welding refers to a discontinuity where the weld metal fails to fuse completely with the base metal or the preceding weld bead. This can weaken the weld joint, leading to potential structural integrity issues. Common causes include inadequate heat input, incorrect welding technique, or poor joint preparation.

What contaminant can be caused from welding?

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Welding can produce contaminants such as metal fumes, gases, and vapors. These contaminants include particulate matter, ozone, nitrogen oxides, carbon monoxide, and other toxic gases, depending on the materials being welded and the welding method used. Proper ventilation and personal protective equipment are essential to minimize exposure to these contaminants.

What is a very toxic chemical when welding?

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Phosgene is a very toxic chemical that can be produced during welding when chlorinated hydrocarbon solvents come into contact with UV radiation from the welding arc. This can occur when cleaning metal surfaces with solvents containing chlorinated compounds before welding. Exposure to phosgene can lead to severe respiratory issues and even death.

What is the purpose of shielding gas in gtaw?

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The purpose of shielding gas in GTAW (Gas Tungsten Arc Welding) is to protect the weld pool from contaminants in the atmosphere, such as oxygen and nitrogen, that can negatively impact the quality of the weld. The gas creates a protective barrier around the molten metal, preventing oxidation and ensuring a clean, strong weld.

What affect does welding polarity have on where heat is directed?

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In DC welding, electrode positive (DCEP) produces more heat at the workpiece, leading to deeper penetration and faster welding speeds. In contrast, electrode negative (DCEN) focuses more heat on the electrode, resulting in shallower penetration and slower welding speeds. AC welding alternates between these effects with each cycle.

How do you test ultrasonic weld?

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To test an ultrasonic weld, you can perform non-destructive tests like visual inspection for any visible defects, ultrasonic testing to check for bond integrity, and pull or shear testing to measure the strength of the weld. These tests help ensure the quality and reliability of the weld.

What is testing weld of ultrasonic?

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Ultrasonic testing of welds involves using high-frequency sound waves to detect flaws or discontinuities in the weld material. This non-destructive testing method can help identify structural defects such as cracks, porosity, or lack of fusion in the weld joint. Ultrasonic testing is commonly used in industries like construction, manufacturing, and oil and gas to ensure the integrity and quality of welds.

What is welding fault of lack of fusion?

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It's when the different metals parts haven't melted together properly

What is the colour of acetylene flame?

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The flame produced by burning acetylene gas is typically colorless when burned in pure oxygen. However, if burned in air, it can produce a slight yellowish flame due to incomplete combustion, which may also contain some soot.

What is the relationship between tack welding and material thickness?

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Tack welding is often used to hold materials in place before final welding. The thickness of the material being welded can affect the size and number of tack welds needed for proper positioning and alignment. Thicker materials may require more tack welds to prevent distortion or misalignment during final welding.

If the electrode used in welding has a moisture what effect will it have on the weld?

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Moisture in the electrode can cause porosity in the weld, as the moisture turns into steam during the welding process, creating gas pockets. This can weaken the overall integrity of the weld and affect its mechanical properties. It is important to keep electrodes dry to prevent these issues.

What temperature does a oxyacetylene torch burn at?

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An oxyacetylene torch typically burns at a temperature of around 3,500 degrees Celsius (6,332 degrees Fahrenheit) when both oxygen and acetylene are mixed and ignited.

A cutting flame that has an excess of oxygen?

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A cutting flame with excess oxygen is known as an oxidizing flame. It is commonly used in metal cutting processes, as the higher oxygen concentration facilitates faster and more efficient cutting by promoting the oxidation of the metal. However, care must be taken to prevent overheating or damaging the material being cut.

What is the tack welding size and spacing in relation to material thickness?

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For tack welding, the general guideline is to have tack weld sizes of 1.5 to 2 times the material thickness. The spacing between tack welds should be approximately 4 to 6 times the material thickness. However, these dimensions may vary depending on the specific welding project and material being used.

What does the flow-meter do in gas metal arc welding?

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The flow meter in gas metal arc welding measures and controls the flow rate of shielding gas that is directed to the welding arc. This helps to ensure a consistent and appropriate amount of shielding gas is provided to protect the weld from atmospheric contamination and achieve optimal weld quality.