Welding and Cutting

Slag in welding is formed when the flux coating on the welding electrode melts and lays over the weld pool. It helps protect the weld from atmospheric contamination, acts as a coolant, and facilitates the removal of impurities from the weld. After the weld cools, the slag can be easily removed.

It is generally called a flux or cleansing agent. Sometimes contained in electrode coatings and found in powdered form to use in the Oxy-fuel welding process. Primary ingredient is Borax ( yah same as in some hand cleaners). Often mixed with water to form a paste that can be applied by a brush to both the welding/brazing rod and also the base metal.

It depends on what welding process is being used and what type of metal is being welded. When Oxy-Fuel Welding, Acetylene is the most popular. MAPP gas and Propane are also used. With the GMAW (MIG) process Argon, CO2 and Oxygen gasses, in mixtures or alone, are used. GTAW (TIG) gasses are almost always Argon and/or Helium. This is not all inclusive as new processes are being developed every day. Check with your welding material supplier for relevant info.

Spatter in welding refers to the small droplets of molten metal that are expelled during the welding process. These droplets can land on the surrounding surfaces and create unwanted weld spatter, which can affect the appearance and quality of the weld. Proper welding techniques and equipment settings can help minimize spatter formation.

The electrode flux coating in welding serves multiple purposes: it provides protection against contaminants, helps produce a stable arc, controls the weld pool shape, and forms a slag to protect the weld as it solidifies. The flux coating also contributes to the overall quality of the weld, improving its mechanical properties and appearance.

Slag in welding acts as a protective layer on the weld pool, shielding it from atmospheric contamination. It also helps to facilitate the removal of impurities and solidification of the weld by providing a controlled cooling rate. Additionally, slag improves the appearance and quality of the final weld by reducing defects such as porosity and cracking.

A welding rod can stick to the metal due to factors such as incorrect amperage setting, contaminated metal surface, or improper technique. When the rod sticks, it may be due to insufficient heat, causing it to adhere to the surface instead of melting and forming a proper weld. Adjusting the settings, ensuring a clean surface, and practicing proper technique can help prevent the rod from sticking.

Tungsten is a metal used as the electrode in Tungsten Inert Gas (TIG) welding. It has a high melting point and is non-consumable, so it does not melt during the welding process. Tungsten helps create a stable arc and allows for precise control in TIG welding.

Welding is a process that involves cohesion, as it involves the joining of similar materials by melting them together to form a strong bond. Adhesion, on the other hand, involves the bonding of different materials.

Yes, hydrogen can be used for welding in certain applications, particularly in atomic hydrogen welding. This process involves using a hydrogen torch to produce a high-temperature flame for welding purposes. However, the use of hydrogen for welding is less common compared to other gases like acetylene or argon.

Arc welding temperatures can range from 5,000°F to 20,000°F, depending on the specific welding process and materials being used. These high temperatures are generated by an electric arc formed between the welding tool and the workpiece.

Argon is good in welding because it acts as a shielding gas to protect the weld pool from atmospheric contamination, such as oxygen and nitrogen. This helps prevent oxidation and produces cleaner and stronger welds. Argon also helps stabilize the electric arc during welding, resulting in better control and improved weld quality.

Ignoring all the normal problems you could have in welding (see other answers) - Argon welding has specific concerns that you normally do not find in other types of welding. Never weld in an enclosed area (without air movement) Argon is a 'heavy' gas that displaces oxygen, if you were to weld with argon above a depression (tank, pit, pipe) the area below could become filled with Argon and entry could cause suffocation and or death. A small space can fill with argon quickly, and a air tight space can fill without detection. Also argon as a compressed gas can cause burns if the line is ruptured (-302F).

The current in welding must be adjusted to achieve the proper heat input to melt the base metals and the electrode, creating a strong bond. Too low of a current can result in incomplete fusion, while too high of a current can lead to excessive heat input and potential burn-through of the base metal. Adjusting the current allows for control over the weld puddle size and penetration depth.

Oxy-fuel welding is a welding process that requires O2 gas. It uses oxygen and a fuel gas, such as acetylene, to create a high-temperature flame for the welding process. The oxygen supports combustion and helps create the heat needed to weld the materials together.

No, sound waves cannot be used to weld materials together. Welding typically involves the use of heat to melt and fuse materials together, with additional methods such as pressure or filler material used to form a strong bond. Sound waves do not generate sufficient heat or force to create a weld.

Oxy-Acetylene. A mixture of oxygen and acetylene.

Commerically it is still acetylene, however, its chemical name is 'ethyne'. Its structure is 'H-C///C-H'.

NB The symbol '///' repreent a triple bond between the two carbons.

A straight weld bead on the surface of a plate with little or no side-to-side electrode movement is called a stringer bead. It is a type of weld bead characterized by its uniform and straight appearance, typically achieved through consistent and controlled forward movement of the welding electrode along the joint.

Oxygen is stored at a much higher pressure than acetylene, which requires a larger cylinder to contain it safely. Additionally, oxygen is less dense than acetylene, resulting in the need for a larger volume to store the same amount of gas.

In dry welding for underwater welding, a hyperbaric chamber is used to create a dry, pressurized environment for the welder to work in. The chamber is sealed to prevent water from entering and is pressurized to balance the external water pressure. The welder enters the chamber through an airlock system and performs welding tasks with the help of specialized equipment and gas supply systems.

Shielding gases in welding protect the molten metal from reacting with the surrounding air, which can lead to defects like porosity and oxidation. They also help stabilize the arc and improve the quality of the weld by controlling the heat input and transfer.

A non-luminous flame is typically used to detect oxygen deficiency, as it burns with a blue color due to complete combustion in the presence of adequate oxygen. If the flame turns yellow or flickers, it could indicate a lack of oxygen and the presence of other gases like carbon monoxide.

To check for defects like incomplete penetration and lack of fusion in welding, you can use techniques like visual inspection, ultrasonic testing, penetrant testing, or radiographic testing. Visual inspection involves visually examining the welded joint to look for discontinuities. Ultrasonic testing uses high-frequency sound waves to detect defects below the surface. Penetrant testing involves applying a dye to the weld and then inspecting for any surface-breaking defects. Radiographic testing uses X-rays or gamma rays to detect internal defects.

In resistance welding, the heat for fusion is generated by passing a high electrical current through the materials being welded. The resistance of the materials to the flow of electrical current causes them to heat up rapidly at the interface, melting and fusing together.

Oxy-Gasoline is an effective fuel and is very good when traditional gas bottles are not available. Hydrogen is a good fuel when welding aluminium but is not used when welding steel because it damages the steel. Propane, butane and butane/propane mixes are also used.