Finland 
Italy
Austria
Belgium
Luxembourg
Netherlands
Monaco
Croatia
Denmark
Greece
Ireland
Portugal
Sweden
Bulgaria
Estonia
Latvia
Lithuania
Poland
Czech Republic
Romania
Slovakia
Slovenia
Hungary
Germany
Spain
France
HOW DOES WIRE WELDING WORK?
What do you need?
First of all, it is important to have a welding generator, a gas cylinder (depending on the material that you are going to weld) with a pressure gauge and a gas hose from the cylinder to the welding machine, a wire coil, and of course a welding torch and ground cable.
The wire welding machine operation can be explained quite simply.
The wire or filler material is wrapped in a coil located inside the welding machine, where 2 or more wire rollers push the material inside the cable bundle to reach the welding liner of the welding torch.
When the wire comes into contact with the material, it closes the circuit created by the ground clamp attached to the material, and it melts, creating the weld.
You must remember that the wire roller is a very important component because, thanks to the motor, it regulates the speed at which the coil unwinds, but also determines the type, thickness and material of wire that can be used with the welding machine.
A prime example is magnesium or silicon aluminum wire, which, being very soft, requires a u-shaped roller that provides more grip on the wire without deforming it, otherwise it would lead to delays in the release of the wire during the welding process.
Another typical case is the roller for flux-cored wire, which has a knurled sliding channel for greater grip on an easily deformed wire.
Wire welding is very common in industrial applications because this process makes it possible to work for extended periods of time without, for example, having to stop to replace the electrode or change the filler rod, unlike with TIG and MMA processes.
The work cycle of a welding machine used on an industrial scale is very high, and the power source is often equipped with a liquid cooling system that is much more effective than normal air cooling.
When welding with gas, the bead is clean because the weld pool is protected from oxidation and cooled by the gas.
It is also possible to proceed with a second or third welding if you need thicker welds, without worrying about cleaning the previous welds.
The only downside of wire welding, especially for domestic use, is the presence of the protective gas cylinder, which is not always practical to handle and manage with annual rentals.
Besides, open welding is not recommended because the shielding gas may be blown away by the wind and the weld bead may be weak and oxidized or have structural problems.
This problem can be solved by using flux-cored wire, which does not require gas protection because it contains a mineral "core" that releases a protective atmosphere over the weld pool when the wire melts, releasing a slag that wraps around the weld bead as it cools down.
The most important and perhaps the most complicated step is setting up the generator, which must be set according to the process that will be used.
What questions should you answer to correctly setup the welding machine?
The questions that you have to answer to obtain a perfect result are:
- - what type of material do you have to weld?
- - what is the thickness of the base material?
- - in what position do you have to weld?
- - has the base material been prepared (caulked) for welding?
- - how many times do you have you weld to complete the job?
- - what do you have to weld? A pipe? An angle? Something flat?
- - what is the wire material?
- - what is the thickness of the wire?
- - at what speed should the wire roller be set?
- - How many liters/minutes should be delivered to properly protect the melting pool?
There is no exact answer to all these questions. There are general parameters on which every welder can rely, but you can't rely completely on them. The art of welding requires a lot of skills and experience.
