Welding For Dummies

Title Page
Copyright Page
Table of Contents
Introduction
	About This Book
	Conventions Used in This Book
	What You’re Not to Read
	Foolish Assumptions
	How This Book Is Organized
		Part 1: Understanding Welding Basics
		Part 2: Welding on a Budget: Stick and Tig Welding
		Part 3: Discovering Mig Welding
		Part 4: Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes
		Part 5: Putting Welding into Action with Projects and Repairs
		Part 6: The Part of Tens
	Icons Used in This Book
	Where to Go from Here
Part 1 Understanding Welding Basics
	Chapter 1 Diving Into the World of Welding
		If You Can’t Beat ’Em, Join ’Em: Understanding Why Welding Matters
			Fabricating metal products
			Repairing metal pieces or products
		Getting Familiar with Metals
			Steel
			Stainless steel
			Aluminum
		Taking the Time to Understand Welding Safety
		Exploring Welding Methods
			Stick welding
			Mig welding
			Tig welding
			Other welding methods
		Looking at the Future of Welding
	Chapter 2 Considering Commonly Welded Metals
		Steeling Yourself for Using Steel
			Getting a handle on forms of steel
			Knowing when steel is appropriate
			Preparing steel for welding
			Exploring steel welding methods
		Going with Stainless Steel
			Understanding the differences between steel and stainless steel
			Deciding when to use stainless steel
			Looking at stainless steel welding methods
		Working with Aluminum
			Perusing the properties of aluminum
			Eyeing aluminum welding techniques
		Considering Other Metals
	Chapter 3 Setting Your Sights on Welding Safety
		Gearing Up to Protect Yourself
			Choosing eye protection
			Keeping the right fire extinguisher on hand
			Wearing protective clothing
			Watching health hazards: Using a respirator and Material Safety Data Sheets
		Observing Basic Safety Rules
			Keeping your work space clean
			Checking for leaks
			Getting the ventilation right
			Storing flammable liquids and gases
			Knowing your surroundings
			Protecting yourself from electric shock
			Shielding yourself from burns
			Maintaining your equipment
		Being Prepared for Injuries and Accidents
			Equipping your first-aid kit
			Knowing how to handle injuries
	Chapter 4 Setting Up Your Welding Shop
		Choosing a Location
			Deciding how much space you need
			Contemplating indoor versus outdoor
		Equipping Your Welding Shop
			Making sure you have the basic hand tools
			Choosing a welding table
			Selecting your welding machine
			Considering a few accessories for your welding shop
Part 2 Welding on a Budget: Stick and Tig Welding
	Chapter 5 Getting on the Stick: Understanding Stick Welding
		Looking at the Pros and Cons of Stick Welding
		Understanding the Factors That Influence Stick Welding
		Getting Familiar with Stick Welding Equipment
			Discovering the differences among stick welding machines
			Setting up your stick welding machine
			Nailing down the basics of stick welding’s electrodes
			Choosing tools and supplies every stick welder needs
	Chapter 6 Getting to Work with Stick Welding
		Preparing to Stick Weld
			Setting up your work area
			Understanding stick welding electrodes
		Setting the Machine
			Choosing polarity
			Setting the amperage
			Preparing to weld
		Striking and Maintaining an Arc
		Assume the Position: Stick Welding in All Positions
			Welding on a flat surface
			Going vertical
			Exploring horizontal welding
			Reaching overhead
	Chapter 7 To Tig or Not To Tig: Understanding Tig Welding
		Taking a Closer Look at Tig Welding Components
		Considering the Advantages and Disadvantages of Tig Welding
		Brushing Up on Tig Welding Basics
			Showing your metal: Looking at a few metals for tig welding
			Taking steps to ensure quality welds
		Stocking the Shop: Examining Tig Welding Equipment
			Considering fully equipped tig machines
			Thinking about tig torches
			Selecting and managing shielding gas
			Controlling current and amperage
			Selecting filler metal
			Exploring tungsten electrodes
	Chapter 8 Trying Out Tig Welding
		Getting Your Welding Setup Tig-ether
			Taking care of tungsten electrode details
			Making sure your shielding gas is set up correctly
			Figuring out your tig filler rods
		Matching Materials and Settings
		Getting a Handle on Using Your Tig Torch
			Choosing an electrical current and striking the arc
			Get a grip: Holding your tig torch correctly
		Giving Tig Welding a Try
			Tackling the first weld
			Trying a butt joint
			Welding a lap joint
			Making a T joint
Part 3 Discovering Mig Welding
	Chapter 9 Understanding the ABCs of Mig Welding
		Understanding How Mig Welding Works
		Considering Mig Welding’s Advantages and Limitations
		Bringing Out the Big Guns (And Other Mig Welding Equipment)
			Mig welding machines
			Mig welding guns
			Electrode wire feeders
		Sifting Through Shielding Gases for Mig Welding
		Taking a Look at Electrode Wire
		Adjusting Mig Equipment to Suit Your Mig Welding Project
	Chapter 10 Practicing Mig Welding
		Preparing to Mig Weld
			Getting the equipment ready
			Setting the wire feed speed and voltage
			Settings for flux-cored arc welding
			Settings for aluminum MIG welding
		Trying Out Mig Welding
			Making vertical mig welds
			Joining pieces of sheet metal
		Watching Out for Common Mig Welding Defects
Part 4 Getting Fancy: Plasma Cutting, Oxyfuel Cutting, and Other Processes
	Chapter 11 Examining Plasma and Oxyfuel Cutting
		Understanding Plasma Arc Cutting
			Identifying some good materials for plasma cutting
			Taking a look at plasma cutting’s advantages and disadvantages
		Perusing and Preparing Plasma Arc Cutting Equipment
			Getting a handle on plasma cutting equipment
			Setting the equipment up properly
		Exploring Oxyfuel Cutting Basics
			Considering what you can (and can’t) cut with oxyfuel
			Looking at the pros and cons of oxyfuel cutting
		Checking Out and Setting Up Oxyfuel Cutting Equipment
			Examining oxyfuel cutting equipment
			Deciding among different gas cylinder sizes
			Setting up oxyfuel cutting equipment
	Chapter 12 Ready, Set, Cut! Trying Out Plasma Arc Cutting and Oxyfuel Cutting
		Exploring Plasma Arc Cutting
			Slicing a straight line
			Cutting a circle
			Creating a bevel
		Practicing Oxyfuel Cutting
			Lighting the torch
			Making a straight cut
			Cutting out a circle
			Taking on a beveled edge
	Chapter 13 Exploring Special Weld Processes
		Working Through the Basics of Welding with Gas
			Taking a gander at gas cylinders
			Looking at more gas welding equipment
			Getting to work with gas welding
		Discovering Brazing (Braze Welding)
			Keeping a few brazing rules in mind
			Giving brazing a try
		Finding Out about Fusion Welding
		Soldering On: Exploring Soldering
			Following the rules of soldering
			Understanding the two types of soldering
			Trying the soldering process
	Chapter 14 Exploring Pipe Welding
		Delving into the Different Kinds of Pipe
		Getting Down to Welding Steel Pipes
			Getting set up and preparing the pipe
			Making the tacks
			Welding the pipes
			Trying some other angles
		Peeking at a Few More Types of Pipe Welding Joints
		Keeping an Eye Out for Common Pipe Welding Defects
	Chapter 15 Working with Cast Iron
		Casting Light on the Three Most Common Types of Cast Iron
			Gray cast iron
			Malleable cast iron
			Nodular cast iron
		Getting the (Cast) Iron in the Fire: Welding Gray Cast Iron
			Stick welding cast iron
			Oxyfuel welding cast iron
			Mig welding cast iron
Part 5 Putting Welding into Action with Projects and Repairs
	Chapter 16 Two Welding Projects to Boost Your Welding Shop
		Creating a Torch Cart
			Gathering the materials
			Acquiring the right steel pieces
			Measuring and cutting pieces
			Making the welds
			Adding the wheels
			Checking your welds
			Picking out your paint
		Fabricating Your Own Portable Welding Table
			Rounding up your tools
			Picking out the parts
			Assembling the pieces
			Ensuring smooth edges
			Choosing your paint
			Putting on the wheels
	Chapter 17 Constructing a Campfire Grill
		Fabricating a Campfire Grill
			Getting your tools in order
			Obtaining the proper steel pieces
			Cutting the steel pieces to length
			Welding the grill
			Picking out your paint
			Seasoning the cooking surface
	Chapter 18 Fixin’ to Fix Things: Analyzing and Planning
		Determining Whether Something Is Fixable
		Planning a Repair Strategy
			Identifying the metal and what it means for the repair
			Deciding which welding process to use for your repair
			Making and following your plan
		Getting Ready to Make Repair Welds
			Preparing your repair piece and work area
			Gathering your equipment and tools
			Selecting filler rods and electrodes
		Considering Cracks
Part 6 The Part of Tens
	Chapter 19 Ten Tools Every Welder Wants
		4½-Inch Grinder
		Hacksaw
		Air Compressor
		3⁄8-Inch Electric Drill
		Wrench Set
		Steel Sawhorses
		Cutoff Saw
		Bench Grinder
		Bottle Jack
		Toolbox
	Chapter 20 (Not Quite) Ten Advantages of Being a Certified Welder
		More Job Opportunities
		Better Pay
		More Chances for Advancement
		Certification that Travels with You
		Ability to Join a National Organization
		Qualification in Specific Areas of Welding
		Increased Confidence in Your Welding Skills
		Listing in the American Welding Society Database
		A Head Start on Additional Types of Welding Certification
	Chapter 21 (Almost) Ten Welding Defects
		Incomplete Penetration
		Incomplete Fusion
		Undercutting
		Slag Inclusions
		Flux Inclusions
		Porosity
		Cracks
		Warpage
		Spatter
	Chapter 22 Ten Signs You’re Welding Correctly
		The Weld Is Distributed Equally between Parts
		The Slag or Shielding Material Doesn’t Stick to the Weld
		No Holes or Irregularities on the Weld Surface
		The Weld Is Tight
		The Weld Is Leakproof
		The Weld Has Full Penetration
		The Weld Has No Undercutting
		The Weld Has No Overlap
		The Weld Meets Strength Requirements
		You’re Safe and Healthy
	Chapter 23 Ten Maintenance Tips for Your Welding Equipment and Shop
		Checking on Your Hand Tools
		Taking Care of Power Tools
		Doing Basic Housekeeping in the Shop
		Protecting Your Welding Helmet
		Seeing to Stick Welding Machine Maintenance
		Working on Maintaining Your Mig Welding Machine
		Tuning Up Your Tig Welding Machine
		Taking Care of Your Oxyfuel Equipment
		Keeping Your Air Compressor Working
		Drill Press Maintenance
Glossary
Index
EULA