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Significant Disadvantages of the Welding Process

There are two significant disadvantages of High Frequency Welding Machine this welding process: a) the full focus and concentration the process requires; and b) its inapplicability in certain cases.

Full focus and concentration is needed during the entire process since it entails constant contact between the electrode and the welding arc; thus, even the mundane act of scratching one's hair is not possible.

With respect to the second disadvantage, the process is inapplicable in welding thick steel due to its inability to penetrate well the surface. Also, when surfaces of metals are not clean, this welding process cannot produce optimum results.

Indeed, the disadvantages of MIG welding are outweighed by its advantages, particularly the simplicity of its procedure. Such simplicity allows even an inexperienced user to weld by himself a few broken fixtures at home.

It is common knowledge that safety aspect should be of paramount concern when it comes to welding. Welding operations produce sparks with a big risk of fire accidents and things in the surrounding area could possibly get ignited.

MIG welding, though it generates a lot of heat and harmful light, can still be absolutely safe as long as you follow all the important safety precautions.

As a first step, you should permanently position a fire extinguisher near the welding area. It is better to have CO2 type of fire extinguisher when welding. Water extinguishers may be inappropriate in a welding shop since you will be standing amidst a whole lot of electricity.

Make sure there is adequate ventilation in the welding area so that the harmful fumes do not suffocate you. Wear either a mask or a respirator if you are going to be welding for a prolonged period of time.

The light that is generated by any type of welding is extraordinarily bright and can burn your eyes and your skin just like the scorching sun if you do not adequately protect yourself. Therefore, the first thing you will need before beginning your welding work is a welding mask.

It is preferable to wear auto-darkening welding mask as it is safer if you are going to do welding for long hours or be working with metal often. Unlike manual mask, auto-darkening welding mask allows you the freedom to use both your hands to weld, and not bother about repeatedly adjusting the mask. Use a welding screen as well to protect others around the welding area from the blinding light.

Never indulge in MIG weld if water is in contact with you or there are water pools around your welding surface. This is necessary to avert all possible chances of electrocution.

Due to excessive heat, your skin and hair can burn and it therefore is necessary to wear long sleeve shirt and non-flammable long pants without cuffs. Use leather welding gloves and an effective eye shield or welding hood. Some people prefer thin gloves for welding for better dexterity of both wrist and palm - but for MIG welding you can wear whatever gloves you feel comfortable with.

The leathers will not only protect your skin from the heat produced by welding but they will also protect your skin from the UV light produced by welding. Please remember UV burns occur suddenly and spread rapidly and you need to be extra guarded.

If you are not able to wear leathers, then you should at least switch to wearing cotton clothes. Plastic fibers like polyester and rayon should be scrupulously avoided as they will melt when coming into contact with molten metal and will positively burn you. Cotton will at the most create a hole and not burn or do anything fatal.

Never wear open toed shoes or synthetic shoes that have mesh over toe top. There is all likelihood of hot metal dropping straight down and burning holes through the tops of the shoes. Wear leather shoes or boots or at least cover your shoes with some non-flammable material.

Please be aware that materials like sawdust, paper or plastic bags in the vicinity of the welding area can smolder and catch fire - so keep the welding are neat and tidy and free from inflammable articles. Your attention will obviously be focused on welding and it will not be possible for you to notice what is happening around you even if something suddenly catches fire.

For over a hundred years arc welders were used for fusing pieces of metal together to produce various products. With many innovations this system has proved to be very practical. But as modern production methods demanded a faster more economical welding method that did not require extremely qualified welders became necessary. The basic arc welding system uses electricity to produce an arc between a coated welding rod and the metal to be welded. Although a simple enough process in detail it actually required a fairly competent welder to produce satisfactory welds at an economical rate. The process also has other faults.

The welding rods are short in length, 12 to 16 inches, to make it possible to properly handle them. Because they are consumed as the welding progresses the welder needs to stop every couple of minutes to load a new rod. He also needs to adjust the distance from the metal as the rods are consumed and become shorter while at the same time maintaining the proper arc distance. This requires practice. In addition the coating on these rods which is used to shield the weld puddle from the atmosphere leaves a coating on the finished weld called slag. In most cases this slag must be chipped off and wire brushed before the welding can continue. This can be a slow tedious job.

To solve these problems an arc welding machine called a MIG, (metal inert gas), has appeared. While the welding is performed by producing an arc between the welding torch and the metal as in standard arc welding, the actual process is vastly different. First and very important a MIG welder uses pressurized gas to shield the weld puddle. This system leaves a clean weld without slag which means that the welder no longer has to spend time cleaning each weld before he starts the next one.

Instead of a short consumable welding rod the MIG system uses a large coil of bare welding wire which can be fed through the welding torch at a controllable rate. While doing so the welder can maintain the arc by holding the welding torch in the same position at all times. The welding torch has a trigger which when pulled feeds the wire and starts the electrical current needed to produce the welding heat. The shielding gas is also turned on as the wire is fed and shields the weld puddle without leaving an residue which would need to be cleaned. This system allows the welder to work for long periods of time on long welds without stopping to replace his welding rod.

About once per shift or less the welder will replace the empty wire coil with a new roll of wire and perhaps will need to replace the gas bottle.RF Welding
  Other than these chores he is free to spend his time completing welds at a very economical rate. Any fairly competent person with normal eye site and standard mechanical can be taught to be a production welder in a short time.