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HOW TO MAKE PERFECT WELDING
On the various blogs that are all over the Internet dedicated to welding, metallurgy or, more simply, to the DIY sector, users exchange ideas, opinions, advice, and animatedly discuss how and what it takes to make a perfect welding, or, more specifically, how to make a perfect welding.
Since welding, by definition, is a process involving several factors, these must be in synergy with each other to achieve a perfect welding.
The most important factor for perfect welding is to have a welding generator that generates the right power and that can produce the correct amperage for the project. For example, it is impossible to make a perfect electrode welding on less than millimeter thick plates, since the electrode coated process generates a large amount of heat compared to other welding methods, and therefore on very thin plates it is easy to pierce the material.
Even the use of an undersized welding machine does not allow for perfect electrode welding. If you have to use an electrode with a 4 mm diameter and the welding machine generates a maximum of 100 Amp, the current is not enough, and the welding generator will stop very often to cool down because its work cycle is only suitable for minor domestic maintenance.
Therefore, as mentioned above, to achieve a perfect welding you need a welding machine that can handle the workload.
The condition of the equipment and consumables used by the operator are also fundamental elements in achieving a perfect welding. The protective equipment used by the operator is extremely important. The use of a welding mask with a screen that is too dark or dirty due to previous welding operations may compromise the operator's visibility, who, without a clear view of the weld poo, may not be able to weld properly.
The quality and state of maintenance of consumables is also extremely important for a perfect electrode welding.
An improperly stored coated electrode loses the physical and chemical qualities of the coating, which must be maintained in optimal storage conditions. If not properly stored, the electrode may have difficulty igniting or tend to quench and during welding may generate an abnormal amount of weld slag, which makes achieving a perfect welding a real challenge. In the worst cases, the slag loses its effectiveness in insulating the bead, oxidizing it while it is still glowing. If you are using old or improperly stored coated electrodes, it is a good idea to heat them in a domestic oven to try to remove moisture from the coating, improving welding properties.
To obtain a perfect electrode welding, the ground and electrode holder clamps must also be in good condition, the contact elements must be clean to allow the flow of current, and the cable coating must be intact for both safety and optimum performance.
To obtain perfect welding, the quality of the metal and its condition are also fundamental factors, and the base material must be clean.
If the base material has rust or oil residues, it is essential to clean or remove the layer of dirt until the edges of the clamp are restored to ideal conditions. Otherwise, rust oxide or a possible inclusion of oil in the weld pool may compromise the structure and thus the weld bead. The base material must be absolutely unpainted to avoid compromising the perfect welding.
Once you are sure that all these requirements have been met, the most important and fundamental element for making a perfect electrode welding comes into play: the personal experience of the welder.
To obtain perfect welding, the operator must be an expert in establishing the welding parameters according to thickness, welding position and material used. Only after a series of tests the operator knows and is familiar with the welding machine he uses.
To make perfect electrode welding, it is necessary to have good manual dexterity and to perfect the welding technique test after test, electrode after electrode, until you achieve the result that you want.
To check whether the operator has made a structurally and aesthetically perfect welding, you can perform a non-destructive test using penetrating liquids. The penetrating liquid may be any color, but it is commonly red, and the white detector, which does not damage the weld and highlights the presence of cracks and any slag on the edges of the weld bead. This is a great test to confirm whether the welding is perfect or not.
