The TAB Guide to DIY Welding: Hands-on Projects for Hobbyists, Handymen, and Artists

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PART 1

Metalworking 101

CHAPTER 1

Safety First

CHAPTER 2

Welding 101

CHAPTER 3

Steel

CHAPTER 4

Metalworking Studio

CHAPTER 5

Basic Hand Tools

CHAPTER 6

Grinding and Cutting

CHAPTER 7

Drill Press

CHAPTER 8

Roll Bending

CHAPTER 9

Oxygen-Acetylene Torch

CHAPTER 10

Plasma Cutter

CHAPTER 11

Metal–Inert Gas (MIG) Welder

CHAPTER 12

Finishing

CHAPTER 1

Safety First

Welding and metalworking have many inherent risks. Anytime you’re working with high heat, bright light, electricity, heavy materials, loud noises, and rotational tools, there is a chance for injury. By keeping a handful of tips in mind, you will be able to work safely for many years to come. Whether or not this is your first time in an industrial studio, the following basic safety rules are practiced in many artistic and industrial shops and are great habits to adopt. When working around industrial tools, safety should be your number one priority. It only takes a small mistake or lapse in attention to cause serious and permanent damage to yourself or someone around you. I encourage you to take your own safety seriously and make it your first priority.

General Shop Safety

A metal shop can be a fun creative space that gets used for everything from the dirtiest of projects to your very first art gallery opening. By keeping safety at the forefront, you can avoid many accidents.

Know your limits. I find metalworking to be so much fun that sometimes I’d rather work through lunch than take the 45 minutes to relax and grab a snack. I can tell you from experience that pacing your workday properly is crucial. Take frequent breaks to admire your work, plan the next steps, and hydrate. This isn’t a race, so take your time and enjoy the ride!

Metalwork doesn’t mix with alcohol or drugs. Being in the proper state of mind when working will help you to avoid accidents.

For more safety information and guidelines, check out the manuals that come with each tool. They will tell you what specific type of protective equipment should be worn and if there are any special considerations. The U.S. Occupational Safety and Health Administration (OSHA) is a good resource for questions relating to material and workplace safety. Although it is intended for employers and employees, much of the information is relevant even for a small home shop. Try a computer search for welding or the name of a specific tool or material to view full OSHA regulations.

Every shop should have a number of safety items and first aid available. There should be a number of functioning fire extinguishers readily accessible and at least one first aid kit with Band-Aids, eyewash containers, antiseptic, and burn ointment. Some shops will have a plumbed eyewash station that should be used if any chemical finds its way into your eyes. You’ll learn more about fire protection later in this book, but if your shop is a shared space, there should be an emergency plan. A phone for emergency calls should be available as well.

Shop Hazards

Sharp Stuff

The metal shop you’re working in will without a doubt have lengths of metal somewhere in it. These can be sharp and frequently have a burr on the cut edge. Sharp metal such as this can cut, poke, tear, and cause serious injury. Taking care to store material in a safe place is critical.

Dirty Stuff

With grinding and welding going on, some serious metal dust will be created. This dust collects on just about every surface it can, so if you wind up with a cut or wound, make sure to clean it out immediately with running water and antiseptic. Cover it with a bandage for the rest of the time you are in the shop.

If you feel like there could be something in your eye, wash it out with eyewash immediately. Do not rub your eye because that could cause the particle to become embedded and would require a trip to the doctor or emergency room.

Metal shops always should have available an eyewash station or eyewash containers. If while working you feel anything start to irritate your eye, do not scratch it; rather, make your way to the eyewash area, and flush out your eye or eyes for a minute or two. Scratching a potential foreign object will, nine times out of ten, cause it to become embedded and require a trip to the eye doctor or emergency room.

Heat and Fire

Nearly every tool you are going to use in this book creates some sort of heat. The metal–inert gas (MIG) welding arc and plasma arc both create heat well over 10,000°F. An oxygen-acetylene torch burns at over 6,000°F. Friction from grinding wheels and cutoff disks can create heat up to 1,000°F. Since steel is a good conductor, as soon as heat is introduced, it begins to spread out quickly. For this reason, you should always wear insulated gloves and be aware of areas that were welded recently so as to not rest tools or place any exposed skin near them. Long after steel has stopped glowing red or orange, it still may be very hot to the touch, enough to cause serious burns.

A good practice in metal shops is to put any recently heated metal in a special place, such as directly under the worktable or against a certain wall. The work can stay there until it is cool to the touch. Particularly in blacksmith shops, a bucket of water is kept handy for quenching hot work. This has special applications for blacksmithing and isn’t as useful in a welding shop except for cooling work (only occasionally). Mild steel doesn’t respond to quick cooling like steel containing more carbon. If you quench mild steel in cool water, the steel is not going to become harder. Rather, the rapid cooling can add stress to a recently welded joint, potentially jeopardizing its strength.

CAUTION: Never put a heated tube into water to cool. The water will instantly turn to steam inside the pipe and can shoot out toward you.

The sparks caused by welding, plasma cutting, torch cutting, and grinding have the potential to start a fire. Don’t let this happen—keep the workplace free from flammable items such as rags, sawdust, paper goods, and other fuel sources. Sparks tend to dance across the floor and can travel quite far. If a stray spark lands on any of the materials just listed, you could very quickly have an emergency on your hands.

Clothing items for metalworking should be made out of natural fibers. Wool, cotton, and leather are just about the only acceptable materials for metal shop work wear. Never wear anything synthetic! The heat and sparks can cause synthetic material to burn and/or melt, introducing the risk of serious injury.

CAUTION: Never keep a lighter in any of your pockets while metalworking. The plastic casing on the lighter can melt when it comes in contact with a hot surface, causing an explosion.

Intense Ultraviolet Radiation and Light

One of the most unique safety issues to keep in mind when welding, plasma cutting, and working with an oxygen-acetylene torch is the ultraviolet (UV) radiation such processes produce. Ultraviolet radiation is what comes from the sun and is responsible for giving you a nasty sunburn, not to mention that the bright light causes light spots in your vision if you accidentally look at the sun. For safety sake, you must treat your arc and flame just like the sun—only this sun is much, much closer. Just like sunburn, a burn from a welding light gives no advance warning. Spend even a short time welding with exposed skin, and a burn can appear. When welding and plasma cutting, cover your face, neck, torso, arms, and hands at all times. The same rule of never look directly at the sun goes for your arcs and flames as well. You should never look directly at them unless you are looking through the proper filter or shade.

With that said, if you get flashed by a neighbor’s welding arc or even your own, quickly look away and/or move away from the welding light, and you shouldn’t suffer any serious damage. If after being flashed you notice light spots in your vision, take a quick break to make sure that those spots go away completely. On occasions when I’ve been flashed, I always notice feeling a little distracted or even dizzy, and I choose to take that chance to grab some water or take a rest. Longer exposures can result in a condition known as arc eye and is described as a sensation of having sand in your eyes. If you ever notice changes in your vision that do not go away, contact your eye doctor immediately.

To keep the risk down of accidental flashing, you should always erect welding screens around your worktable. Depending on your workspace, you may need four screens to go all the way around your space. These screens also help to keep any sparks from traveling too far away.

NOTE: Wear dark colors when welding because even indirect reflected light off of clothing can cause damage to your vision.

Electricity

Electric tools such as a MIG welder and plasma cutter run on a 110- through 240-V circuit. The higher voltage, usually used in shops and industrial areas, has much more power than a household circuit and must be taken very seriously. Again, the conductivity of steel can be a problem if an electrical cord shorts out on a length of steel on which you are working. If a hot piece of your work rests on an extension cord for long, it will melt through the shielding and can cause a shock. Inspect all electrical connections regularly, and replace any damaged cords or plugs. Always use caution when plugging and unplugging tools, and never remove coverings or the guards from a tool in use.

Fortunately, the risk of electrical shock while welding is very low because electricity looks for the path of least resistance when completing a circuit. Steel is a much better conductor than your skin or leather gloves, so the current will flow easily through the metal. However, loose electrical connections in the welder and working in a damp environment can increase the risk of shock greatly. For these reasons, make sure that all your electric tools are in good shape and that you are not welding in wet conditions or when your clothing is damp. Always wear rubber-soled shoes, insulated gloves, and protective clothing to help minimize the risk.

Chemicals

Most metal studios have some sorts of lubricants, paints, solvents, and other common chemicals nearby. Many of these chemicals are flammable and/or combustible. Chemicals always should be labeled and stored properly where heat, sparks, and flame can’t come in contact with them. Usually the best option is a fireproof locker or cabinet.

Gases

For welding and torch cutting, compressed-gas cylinders are required. The handling of compressed gases should be taken very seriously because these cylinders are big, heavy tanks with an internal pressure that can be around 2,000 lb/in². If one of these tanks gets knocked over or develops a hole, a lot of force is unleashed very quickly. Oxygen gas and carbon dioxide and argon gas mixtures are not flammable on their own, but the acetylene gas you use for torch cutting is extremely flammable. More storage techniques will be covered when I talk about the workshop, but here you’re going to learn the basics of compressed-gas cylinder handling:

1. Compressed-gas cylinders always must be secured. This means that when stored, transporting, and in use, all gas cylinders should be secured in the vertical position. If they are not secured properly, damage could occur to the valve, allowing gas to escape. When not in use and for transporting, cylinder valves should be covered properly with their valve cap. A handcart with restraint strap or chain must be used when moving gas cylinders around the shop space. Transporting gases in a vehicle that isn’t designed to do so can be dangerous. To keep yourself and others safe, always have your gases delivered by a supplier. If for some reason this is impossible, follow the link at the end of this section to read about proper transportation of gases in your vehicle.

2. Keep your regulator and valve assembly clean. Particulates lodged in the valve assembly can create leaks in the fittings or regulator, which may lead to an explosion. Since oxygen lowers the combustion temperature for materials, even the most everyday contaminate can become flammable in an oxygen environment. Make sure to blow out the fitting area before attaching a regulator. The brass fittings on gas cylinders and the regulators will form a tight seal as long as nothing is trapped along the threads.

3. Never go above 15 lb/in² on an acetylene regulator. Acetylene gas is combustible above 15 lb/in². If acetylene gas gets compressed over 15 lb/in², it will likely cause an explosion. Always use extreme care when opening an acetylene valve to make sure that the pressure does not increase rapidly.

4. Never use an acetylene cylinder that has been laid down. Thus, if the other gas cylinders are filled to 2,000 lb/in² and acetylene is combustible at 15 lb/in², how do they compress the gas in a cylinder? This brings me to the final gas cylinder-handling note. Acetylene cylinders contain a mixture of acetylene gas that’s been dissolved in acetone, all of which is suspended in a porous structure inside the tank. When an acetylene cylinder is laid on its side, the acetone can flow into the valve, which would cause regulator failure.

If you are working in a shared metal shop, make sure to check with the shop manager about gas safety. If you are setting up your own workspace, you’ll need to arrange a gas rental plan with a local supplier.

Most important, read all safety warnings and labels that come with the specific tools and equipment you use so that you understand how best to use them.

NOTE: For more information on compressed-gas cylinder safety, download the Cylinder Safety .pdf from BOC World of Welding (www.bocworldofwelding.com/).

Personal Protective Equipment (PPE)

Clear Safety Glasses and Face Shields

Whenever you are in a metal shop, whether you’re working or just passing through, wear safety glasses. No matter what. Wear safety glasses. One more time, wear safety glasses. Given the presence of tools that rotate at high speeds, long lengths of metal, sharp objects, sparks, metal dust, and a plethora of other dangerous things, there are many ways in which your eyes could be in danger. By simply putting on eye protection, most injuries can be avoided. Even if you wear regular glasses, find a pair of safety glasses that fit over them and cover the top and both sides. I highly recommend spending some time to find a pair of safety glasses that fit comfortably and that you keep those in good shape. If you have an extra eyeglass case around the house or an old sock, devote it to the protection of your safety glasses, and they will be with you for a long time!

For angle grinding and chop sawing, you may want to increase protection over your whole face. For this I recommend using a clear acrylic face shield. These shields should be worn over your safety glasses because they don’t protect your eyes as well as safety glasses alone (Figure 1.1).

FIGURE 1.1 Examples of clear safety glasses and face shields.

CAUTION: Remember that safety glasses do not offer protection from the extreme light produced by welding or plasma cutting. For those processes, you will need to wear protection that is rated at the proper shade (see Tables 1.1 and 1.2).

TABLE 1.1 Shade Number Guide for MIG Welding

TABLE 1.2 Shade Number Guide for Plasma Cutting

Welding Helmet

MIG welding creates UV light and radiation that is bright enough to cause serious eye damage within seconds and will dry out and burn any exposed skin. For this reason, never look at a welding arc for any amount of time without proper eye protection or stand near an arc with exposed skin.

Welding helmets provide protection against this extreme UV light, heat, and sparks (Figure 1.2). They feature a hard shell that wraps about halfway around your head and covers some of your neck. The shell should pivot on an adjustable cradle that conforms to your head. In the middle of this shell is a rectangular window called the shade or filter. Shades are rated in darkness numbers 1 through 14 (14 being the darkest). The required darkness of your welding shade will depend on the type of welding or cutting you are planning to do (see Table 1.1). For general MIG, tungsten-inert gas (TIG), and stick welding, a shade rated between 11 and 14 is recommended. To give you an idea of how dark these filters are, if you were in a normally lit room looking through a shade no. 10 helmet, it would seem as though you were looking into pitch black. Only if you look directly at a halogen bulb or the sun will you see any light through it. If you were looking through a no. 8 or 9 filter, you would start to see normal light bulbs and some reflected light around the room. A no. 4 to 5 filter will allow you to see most everything, but it would be like looking through dark-green sunglasses. The key to these filters is that when the welding arc, plasma torch, or oxygen-acetylene flame is created, it produces enough light to illuminate your work area. It won’t look like normal lighting conditions, but it will be enough that you can see the weld pool and surrounding material. It is this environment that will surprise and frustrate most new welders. The first projects in this book are designed to help you overcome this hurdle, and I strongly recommend that you take your time with these and move on only when you are comfortable maintaining a constant arc.

FIGURE 1.2 A welder working safely.

As recently as 20 years ago, there was one main type of welding helmet on the market. This helmet had a shade that was fixed at a specific darkness and required the user to flip the helmet down just before starting to weld. These helmets are called fixed-shade, flip-down, or non-auto-darkening helmets and are shown in Figure 1.3. They are still available today and are very inexpensive, have fewer parts, and require little maintenance. The main disadvantage is that between when you flip the helmet down and strike a continuous arc, you’re basically left in the dark. To use one of these helmets, you must remain very still for this split second so as to not move your electrode and accidentally weld off-target. The other type of helmet that is very popular today is called an auto-darkening helmet, as shown in Figure 1.4. These helmets have a window that changes between a lighter shade (around nos. 3–5) to a shade that is appropriate for welding (nos. 10–14) immediately when exposed to welding light. These welding helmets are battery powered and have a solar panel that charges the battery when you are welding (genius!). They also have a sensor that triggers the shade to darken as soon as a welding arc is detected. These helmets are very convenient because you can see your work environment between stopping and starting the welding arc. For projects in this book, your maximum welding current will be less than 200 A. Take a look at Table 1.1 to see the range of possible shades required for MIG welding.

FIGURE 1.3 Fixed-shade welding helmet.

FIGURE 1.4 Auto-darkening welding helmets.

Every day when you strike your first arc, check to make sure that your auto-darkening helmet switches to the proper shade immediately. If it doesn’t, try charging the battery by leaving it in direct sunlight. It’s a good practice to leave your auto-darkening helmet in direct sunlight for short times when it’s not in use so that it remains fully charged.

Two other types of welding eye protection exist, but I don’t recommend either to beginning welders. The first type is a shield with a fixed-shade filter that you hold between your face and the weld area. For the techniques I’m going to cover in this book, this type of protection isn’t acceptable because you’ll be using both hands to brace the MIG weld gun. It also doesn’t provide as consistent protection as a helmet to the rest of your face and neck. There are also shaded glasses intended for welding use (you’ve probably seen them in old movies), but these provide no protection to your face or neck and aren’t used commonly with today’s welding techniques.

Shaded Glasses and Face Shields (Shade Nos. 4–12)

For plasma cutting, a shade nos. 4-12 pair of glasses, goggles, or face shield always should be worn. Just as with welding, plasma cutting produces intense UV light, extreme heat, and sparks, so proper coverage and eye protection like that shown in Figure 1.5 is crucial. In Table 1.2, the full range of shades is listed for plasma cutting in relation to the machine’s selected arc current.

FIGURE 1.5 Shaded glasses and a face shield.

A face shield also will provide protection against the sparks that inevitably bounce off the surface of the workpiece and toward your face. When you begin plasma or torch cutting, I suggest that you wear a full-face shield until you are accustomed to the sparks. When you are welding, cutting, or bending with an oxygen-acetylene torch, always wear a no. 4 or higher shade facemask or glasses. The exact shade number depends on your personal preference, but anything over a no. 4 shade will prevent injury from UV light produced by the flame.

Gloves

Mild steel melts at around 2,600°F. This is over 2,000 degrees hotter than if you accidentally reached into your oven to grab a pie tin while the oven is still hot. Needless to say, touching any piece of steel with your bare skin shortly after you’ve welded it will cause a serious burn.

There are a few types of gloves that you will want to use when working on a welding project; most importa is a nice pair of insulated welding gloves such as those shown in Figure 1.6. These gloves will protect you from flying sparks, heat, and UV light. Although they are well insulated, heat can—and will—transfer through them if your hand is on or near a hot surface for an extended period of time. If you start to feel heat on the inside of your glove, chances are that within a few seconds that heat is going to get much hotter. This is why MIG welding gloves are slightly loosely fitting. With one or two quick shakes of your wrist, the glove should slide completely off your hand. It will take some getting used to working in these clumsy-feeling gloves, but stick with it and you’ll soon adjust. Wear these gloves when MIG welding, plasma cutting, and torch cutting. They also will come in handy when you need to remove a wire wheel from your angle grinder.