It is obvious that Arc welding is considered as the major and an essential part of all the industries involved in designing and infrastructure. But what arc welding is? It is a process of fusing two metals by applying intense heat. This welding type used welding power supply in order to create an electric arc between base material and electrode. And, the final product that develops contain all the properties, just as in metals. The term arc welding is named because the heat that is used during the process of melting the metal at the juncture of joining is caused by an electric arc. With the help of a mechanically guided electrode, carrying the current between tip and the joint leads to cause of electric arc. Listed here are some of the arc welding tips and techniques for the beginners.
- Safety Precautions
Remember that before commencing with any of the welding methods, you need to adopt proper safety precautions. During welding harmful UV rays and sparks are produced that can damage eyes and skin, so it is important to wear safety glasses to get rid of any kind of damage. Also, wearing helmets during arc welding is mandatory. After all, self protection is a must to reduce risk of fire accidents and electric shocks. So before starting with arc welding, make sure that you have every safety gear ready with you.
- Rod and Arc Setting
This is the one of the most crucial and important parts of this procedure. And, if you are starting with this welding type for the very first time then it is better to do it on a rusty metal work as it is much more tolerant to the rusty surfaces. Also, make sure that your current setting should be in the correct position. And, if you are making use of 2.55mm rods, then make sure to use only 80 amps current supply. Also, polarity settings have to be adjusted. Polarity setting is done in such a way that the rod is positive and the earth is negative.
- Arc Welding Process
At first you need to turn on the welding machine. An electric arc is being generated when the welding rod comes in contact with the juncture of fusion. Generally, Tap Starting and Scratch Starting, are used for the process of electric arc generation. In Tap starting method, an electrode is used to tap on the work that removes excessive flux from electrode tip, which meanwhile creates an electric contact to generate the arc. While in scratch starting method, the rod is made to scratch against the surface of the work slightly and as the spark is generated, the rod can be lifted off. Also, remember not to put extra pressure in the method, because through this the rod might get stuck to the work medium.
Stick welding is known as the process that makes use of a covered electrode called stick. Also, known as Shielded Metal Arc Welding or SMAW, stick welding is the most widely used method today than other welding methods. But, now the question is how do they work?
The equipments used:
Stick welder contains circuitry inside the machine, which enables to carry a specified amount of voltage, therefore creating an arc. And, this is the reason why these welders are sometimes referred to as ARC welders. Totally relying on the application as well as on the machine, the current can be either alternating or direct current. The circuit board, which is present inside the welder enables it to ground the negative to the positive by creating heat without burning the electronics.
Shielded Metal Arc Welding (SMAW)
The welding procedure with the help of stick is called shielded metal arc welding or SMAW. The welding stick is a metal, which is coated with a flux material that burns off when the arc is struck, thereby creating a gas that protects the weld created. This type of welding is the most preferred method for the purpose of large metal structures like building framework, etc., because of its versatility and penetration ability. Although, today, other welding process like Flux-cored welding, or wire feed, is gaining more popularity, but stick welding still dominates the field.
The Weld:-
Factually, there are two types of leads that occurs in a stick welder. One lead is the negative clamp, and the other is the positive lead. In positive lead, the consumable metal stick is placed, while the negative lead is clamped on to the metal that is to be welded. During the process, when positive lead containing the stick comes in contact with the metal, an arc is created that further burns into the metal surface. Throughout the arc burning process, the stick is also burned, which thereby creates the weld. And, this is why welding is considered different than that of soldering process.
Safety Measures
While getting indulged in the process of welding, it is imperative to consider certain safety precautions to get rid of the risky environment. Always make sure to wear a welding hood when striking an arc. It is known that harmful UV rays are produced during the welding that can lead to burn in the eyes, so it is advisable to wear suitable goggles during welding. Also, wear leather welding gloves and a long-sleeved leather jacket, as well as heavy footwear and jeans. Remember, to remove all the inflammable materials from the work area before welding. So, consider the safety measures in order to get clean and successful welding.

Blacksmiths create products from metal. They use iron (or the derivative, steel) which they warm up inside a forge up to the point it is hot enough to work with hammers, chisels and anvils. Blacksmiths make goods such as horseshoes, candlesticks, swords, wrought iron gates, leaded porches, railings, sculpture, tools plus more !.
The expression ‘blacksmith’ originates from the activity of ’smiting’ iron (the ‘black metal’). Iron is called the ‘black metal’ because it goes black if heated in a fire. The ’smith’ bit originates from the word ’smite’ that means ‘to hit’. Therefore, someone who hits iron for a job is a blacksmith.
In fact, blacksmiths also make use of other metals too including copper, bronze, aluminum, brass and titanium, particularly for artistic items. Wrought iron is the purest form of iron, and steel is a mixture of iron and between 0.3% to 1.7% carbon by weight. The more carbon the iron has got, the harder it can be made.Cast iron features between 2.0% to 6% carbon by weight and it is brittle.
Blacksmiths sculpt, weld, heat-treat and finish the metal to get it to the condition they’re aiming for. When the metal is put in the flames, it glows red, followed by orange and yellow which is the best point for the blacksmith to work it. Leaving the metal to keep heating will result in it glowing white and then melting. To create the final item, the blacksmith will use an assortment of the forging processes which are bending, shrinking, punching (making holes and depressions), drawing (lengthening the metal) and upsetting (making the metal thicker in one dimension by shortening it in the other). Welding is used to join two or more pieces of metal together. Finishing can involve polishing and brightening the metal with a wire brush or sandpaper or smoothing burrs and unnecessary sharp edges using a file.The metal could also be finished with paint, oil and wax.
A blacksmith is extremely skilled. They must be aware of the properties of each and every metal they’re using and be able to work speedily before the metal cools down too much.Most of the techniques require good hand-eye coordination and years of practice to perfect.
The very best blacksmiths in the world contend annually in The World Championship Blacksmiths’ farrier Competition in Calgary, Alberta.The best entrant is crowned The World Champion Blacksmith.
Local blacksmiths used to be more common in the days when many people got around using horses. However, it is very important help any nearby blacksmith because it would be incredibly depressing to see the industry die out. Buying a hand-crafted candlestick from a blacksmith is far nicer in comparison with having one that is mass-produced which a great many other people have. Commissioning an outdoor trellis or metal staircase means that you can have a custom piece of work that can last a lifetime and you will be supporting the local economy too, so why not see what your local blacksmith can do for you.

Wanna learn how to TIG weld aluminum?
First you need a decent TIG welding machine. Not a great one, just a decent one. Already got one? You might have an old Synrowave 300 or a DialArc, an old Hobart CyberTIG or you might have a brand new Miller Dynasty 200DX.
Know what? It doesn’t really matter. The same principles apply. If you have an old as dirt TIG welding machine, you can still make good aluminum TIG welds. Weld beads that look like a stack of dimes.
First lets look at machine settings:
Set the polarity to A/c (alternating currrent)
- Make sure to set the high frequency to continuous
- Set the amperage to about one and one half amps per one thousandths of inch of thickness (up to about 250 amps then things change quite a bit)
- Set both the contactor and amperage switches to the remote positon
- Set the argon or argon/helium torch shielding gas to around 15 cfh. (if you are using a #7 cup) less if the cup is smaller
- Notice I said argon or argon/helium? Argon is not the only game in town. In fact, if you TIG weld any aluminum over about .063″ thick, adding helium to the mix makes a huge difference.
Now lets talk tungsten electrodes:
- 2% thoriated have received a lot of bad press for the radioactivity issue but they do work
- 2% lanthanated electrodes are a really good all purpose electrode…good for TIG welding aluminum as well as steel
- Use the smallest electrode that will get the job done without quivering at max amperage.
Remote amperage control…you need a foot pedal. Period.
- Once all the settings are ok, and assuming you are welding on 1/8″ thick aluminum, grab a piece of 4043 filler rod in 3/32 diameter (rarely will you use a rod as thick or thicker than the metal you are welding)
- Extend the electrode tip about 1/4″ past the tip of the TIG welding torch cup and pre purge the gas by tapping the foot pedal.
- Hold the torch like a big first grade pencil. Touch the tip of the tungsten to the metal and then pull it back about 1/8 inch. Flip your helmet down and press the pedal to initiate the arc.
- Don’t melt the aluminum right away though, watch the black stuff cook away from the arcs cleaning action before you melt the metal. Then press the pedal far enough to create a puddle that is about 3-4 times the thickness of the metal you are welding.
Now comes the part on how to achieve the “stack of dimes” look. You get that by adding the same amount of rod and by moving the torch the same distance each time you add rod. Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch,Add rod, Step ahead 1/8 inch, lather rinse repeat. If you do this consistently, you will get evenly spaced ripples that look like a stack of dimes.
Of course it looks different from underneath the welding helmet and it is harder than it sounds, but this is really how you do it. All that is left is the doing. It takes practice and lots of quality seat time.
This part is important, so pay attention Go to my website right now to learn about aluminum welding. While you are there you might learn a thing or two about the Miller Dynasty 200DX as well. My free Welding Secrets newsletter might have what you need, sign up for it, it’s free.