This article focuses on how to weld for beginners and for those who have limited experience or knowledge in the area of welding. It is designed for those who want to learn how to weld and gain the fundamental basics of welding.
What is Welding?
In simple terms, welding is the process of using a high heat to join to objects (usually metal) together. A filler or consumable metal is often used to melt into the weld joint and assist in the joining process. This filler material is typically the same type of metal to that which is being welded. Throughout the welding process, the metal can become contaminated due to particles in the air which come into contact with the welded metal. Each method of welding has its own way of preventing contamination whether it be by the use of a shielded gas or flux coating.
Different Types of Welding
There are various methods of welding depending on the type of work being conducted. The four most popular types of welding are stick welding, flux-cored arc welding, MIG welding and TIG welding. Whilst each method of welding is similar in some ways, it’s important to know the differences between each process. Take a look at the below video or continue reading for more information on each welding method.
Stick Welding
Stick welding also known as Manual Metal Arc (MMA) or Shielded Metal Arc Welding (SMAW) is an arc welding process which uses an electricity supply through the welding machine and into a clamp. The clamp attaches to a solid metal rod (or stick) which is a consumable filler metal that melts into the weld joint. A second clamp is attached to the metal which is being welded in order to create a circuit. This circuit creates an arc that provides an extremely high heat which melts the base metal and the filler metal to join the metals together.
This method of welding differs from other methods such as TIG and MIG as it does not require a gas supply to prevent the metal becoming contaminated. Instead, the metal rod (or stick) is insulated by an exterior coating called ‘flux’ which protects the molten metal from the air to prevent contamination from oxygen and other gases or particles. As the welding process continues, the metal rod will slowly burn off and get shorter and shorter, leaving a metal coating called ‘slag’.
Stick welding is great for those who don’t want to worry about using a gas tank or want to weld thicker types of metals. Stick welding is pretty inexpensive and portable as there is no requirement to have a gas tank. Some of the downfalls are that it leaves a metal coating (slag) which requires removal once the metal has cooled.
Flux-Cored Arc Welding
Flux-cored arc welding (FCAW) is an arc welding process which uses a continuous wire electrode that feeds through the welder. This wire electrode is a consumable filler metal which is tubular and contains flux in the centre. This is opposite to the stick welding method which has a flux coating on the outside.
This benefits to this type of welding method is there is no need to change the filler metal due to the continuous wire feed. This means you can continue welding without the interruption of changing filler materials.
Flux-cored arc welding is great for most types of metals and can be used on all levels of thickness. The only downfall with this method is that it still produces ‘slag’ as a result of the flux filler, much the same as stick welding. This slag requires manual removal once the metal has cooled.
Mig Welding
Metal Inert Gas (MIG) welding also known as Gas Metal Arc Welding (GMAW) is a type of arc welding process that uses a continuous wire electrode which feeds through the welding gun, just the same as the flux-cored arc welding method. The main difference is the MIG welder has a metal nozzle at the tip of the welding gun which is used to produce a shielding gas in order to prevent the metal becoming contaminated. This means that flux is not required as part of the filler and therefore no slag is left behind as it does with other welding methods.
MIG welding produces a nice clean weld and can be used on really thin pieces of metal without problems. One of the downfalls of MIG welding is generally the price as MIG welders are typically more expensive than other welders. Additionally, you need to purchase a gas tank and refill the gas in order for it to work.
If you have a MIG welder and need the extra portability, it can be setup in a flux-cored arc welding format. This means you can take use the welder without the gas tank as long as you have the correct wire electrode which specific to the welding method. This could be a good idea for those who don’t want to fork out the extra cash for the gas tank upfront or those wanting to try the flux-cored arc welding process as an alternative.
Tig Welding
Tungsten Inert Gas (TIG) welding is a type of arc welding process, also known as Gas Tungsten Arc Welding (GTAW). TIG is similar to MIG welding in that it uses a shielded gas to prevent contamination to the metal. The difference being that instead of using a continuous wire electrode that feeds through the welding gun, TIG uses a non-consumable electrode made out of tungsten alloy. This electrode can reach extremely high heat without melting and is used to create an arc to melt metal. TIG requires an additionally consumable filler rod to assist in the welding process and fill the weld joint.
This method of welding is far more precise than other methods and allows for greater control over the weld. However, it is the most difficult welding method to learn and therefore is recommended for intermediate to advanced welders.
TIG welders are similar in price to MIG welders and also require a gas tank which comes at an extra cost. TIG welders can also be used to stick weld if you prefer the extra portability without needing a gas tank or would like to try an alternative welding method.
Best welding method for beginners?
The best welding method to learn for beginners is MIG welding. MIG welding is a simple process to setup and get going. It is the most versatile in that it can be used on most metals and thicknesses. The continuous filler rod allows for uninterrupted welding without the need to replace filler material or change welding position. MIG welders allow you to preselect all your controls including wire speed and shielded gas levels.
Welding Safety
It doesn’t matter which method of welding you use, it’s important to always wear the correct personal protective equipment (PPE) to ensure you are safe from burns and other welding injuries. Below are some of the essential pieces of equipment required to weld safely.
Welding gloves
One of the most important pieces of equipment for welding are a pair of quality welding gloves that are insulated from heat and will protect your hands from burns. These are essential to all welding methods.
Welding helmet
A good quality welding helmet is an essential piece of welding equipment. It’s important to ensure the helmet is equipped with lens filters suitable for the type of welding method you are undertaking. Lens filters will protect your eyes from the bright arc and sparks. A good quality welding helmet will also protect you from flying metal and other particles.
Pants
Full length pants that are made from thick material and aren’t folded at the bottom are essential to all welding methods. This will reduce the likelihood of hot particles falling and becoming stuck between material, causing burns.
Lung protection
Whilst not always used, lung protection is an important consideration when it comes to welding safety. The risk of being exposed to harmful gases and fumes can have a long-term impact on your health if inhaled. A quality respirator is highly recommended, especially for those who weld often or weld in indoors.
Hearing protection
Hearing protection is strongly recommended as anything over 85 decibels is considered harmful for your ears. Welding can range from anywhere between 80 – 118 decibles depending on the type of method be used. Ensure that the hearing protection is thin enough to fit under your welding helmet.
Shoes
Rubber-soled boots or shoes are recommended as they provide better grip and more importantly are non-conductive, reducing the risk of electric shock. If working with heavier metals or machinery, it’s recommended to use steel-capped boots to prevent injury to feet if items fall or are dropped.
Final Thoughts
Welding is a great skill to learn and can be used on a wide range of projects whether as a career or performing some DIY work at home. For those who are new to welding, we recommend starting with MIG welding as it’s a simple process to learn.
Whether you’re a beginner or a veteran welder, we strongly advise having the correct PPE to keep you protected from burns and other injuries.
It’s important to note that nowadays welding machines are available as multi-purpose units, which can perform multiple methods of welding in the one machine. We recommend doing your research and knowing what type of machine you want for the type of welding projects you will be undertaking.
We hope this article has given you a basic understanding of how to weld and an introduction to the different welding methods.
