How to become a better welder

Picture of a welder using the shielded metal arc welding process.

Todays society demands quality, stability, strength, as well as a mountain of other things. Thats why we need good welders to produce our every day crafted items from buildings to auto parts to farm equipment. All walks of life are impacted by welding.

Things You'll Need

• Welding power supply and feed system (if aplicapable)
• Proper consumables (tips wire/rods ect)
• Safety gear or PPE

Instructions

1. Ok now that you have all of your welding equipment we can review some steps and tips to make you a better welder. Having been working as welder for several years I have seen a lot of things that we overlook that can increase productivity and quality WITH OUT compromising safety.

2. 

   Ok starting simple and from the basics. Look over your equipment. Start with the Personal Protective Equipment (PPE), check for missing, broken, tattered, or worn items. You will never complete a welding project it the batteries in your auto darkening helmet are dead or the lens are burnt or the gloves are full of holes letting spatter get in. Lost time due to an injury is a waste of all resources and it leaves you feeling less than 100%.

   Checking the welder for a worn tip or a clogged nozzle as well as a undercut or kinked liner will also increase productivity as well and produce a better looking and stronger weld.

   Replace all the things needed and take a spare tip, nozzle, and diffuser with you just incase. Doing this now will keep you from having a breakdown of your welding in the middle of a crucial weld.

3. Next step is to get to know what you welding. Look over the blue prints and the materials. Doing this can allow you to think ahead and be prepared with all the tools you may need as well as consumables. A blue print may call for the work piece to be prepared with a grinder to produce a bevel or groove. I may also call for hammering the weld. Knowing this lets you gather the proper tools before you start the job.

   Also knowing the materials is a good idea. Some metals need preparation while some don't. Mild steel should be cleaned of shipping oils and the such just like aluminum should be brushed with a clean dedicated wire brush. All these things could cause a poor weld if the proper steps are not taken.

   Think of it like this would you want to drive on a bridge that was welded by some one that welded it fast to get it done or on one that the welder took the time to ensure that her did it right?

4. The next step is to set the machine. Grab some scrap metal of the same type you are working with, strike a arc and then make adjustments to the voltage and wire speed. Thin gauge metal such as 16 gauge needs needs a lot lower settings than that of 1/2 inch steel. Use the blue print or the specs that came with the welder to help get a ballpark figure so you don't burn through, distort the metal, or not fully penetrate the work piece. Also you do not want a "cold weld" either. These welds are brittle and tend to crack and break away.

   Proper machine settings allow for a better weld and it maximizes the life of the consumables. Making consumables last as long as possible and producing a quality weld will allow you to charge a fair price causing the customer to return when they have future welding needs.

5. Next, remember the basics. All the things we were taught when we first picked up the mig or tig gun. Maintain your tip to work piece distance to close or to far away can produce flaws in your weld. Remember drag angles as well as gun control. This can mean "whip and pause" or the motion in which you move the tip along the weld. Travel speed versus the wire speed should always be kept in mind.

   These sort of "rookie" things tend to get overlooked sometimes. It can make a huge difference in pulling or pushing a weld pool.

6. The next thing and perhaps a key item is training. Get trained on new equipment as it hits the market or is incorporated into your work place. If training is unavailable read up on the equipment or contact the manufacturer or the vendor. If you spend money on a piece of equipment they should be happy to get you a tutorial on proper usage. Staying current on the technology in the industry will allow you to stay proficient with your skills allowing you to be the best of the best.

Tips & Warnings

• Practice also helps develop good technique.

• Take courses at local colleges, most employers will reimburse for the tuition.

• Follow the shop guidelines for PPE, hearing protection, eye pro, steel toes, and etc. Those items can prevent serious injury.

• Never weld with out the proper PPE. The arc can cause blindness and flash burn to the skin and eyes.

• Use the proper welding process and the proper consumables. Not doing so can lead to a faulty weld.

• Welding should be done in a area that is not closed off to ventalation, coatings on the metal i.e. galvanization can be extremely hazardous if inhaled.

• Follow the manufactures recommendations for best results regarding equipment use and safety.