Welding Basics : Tractor Supply Company

Welding Basics

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Electric Welding Basics
Types of Electric Welding Processes
Plasma Cutting
Electric Welding Glossary
Oxygen-Acetylene Torch Outfit Basics
Types of Electric Welding

Stick Welding
Wire Feed Welders / MIG Welding
Flux Cored Arc Welding
TIG Welding
Resistance Spot Welding

Types of Torch Outfit Processes

Cutting
Heating
Welding (Fusion)
Brazing (Adhesion)

What Type of Metal Do You Need?

Electric Welding
Torch Processes

The Thoroughbred Industrial Cylinder Exchange

Cylinder Size #2
Cylinder Size #3
Cylinder Size #4

Frequently Asked Questions
Appendix

Electric Welding Basics

Are you a do-it-yourselfer with a question about welding? With all the stuff you need to get your welding job done and all the people with the know-how to help you do it, Tractor Supply Company is your welding destination. Here are some tips to help you along. If you don't find what you need on this page, visit your local store and an expert team member will be happy to help.

Electric welding is the joining of metal using an electrical arc and a filler metal (stick electrode or wire). Welding is done by creating an arc between the base metal (the metal being welded) and the filler metal. The arc melts the base metal and filler metal, combining them into one material to join the base metals. The filler metal is consumed in the process.

Note: Flux cored welding (FCAW) works like MIG welding, except flux cored welding does not require an external cylinder full of shielding gas.

Types of Electric Welding Processes

There a number of different electric welding processes. While most of the processes work with steel, no one process works with every type of metal. The following table indicates which process is recommended for which type of metal. The different types of welding processes will be discussed in detail in the next section of this module.

Metal Type	Electric Welding Process

	Stick	MIG	Flux Wire	AC-TIG	DC-TIG	Resistance Spot
Steel	X	X	X		X	X
Stainless Steel	X	X	X		X	X
Aluminum	X	X		X
Cast Iron	X
Copper/Brass					X
Magnesium Alloys				X
Titanium					X
Skill Level	Moderate	Low	Low	High	High	Low

Plasma Cutting

Plasma cutting works on all electrically conductive metals: steel, stainless steel, galvanized, copper, brass, and aluminum. Plasma cutting uses an electric arc and compressed air to generate its cutting power, so there is no need for gas cylinders. Plasma is known for producing clean accurate cuts with a minimal heat affected area. Plasma cutting reduces warping, which makes it a popular method for working with thin materials, such as in auto bodywork.

You can find plasma cutters online at TractorSupply.com or at your local store.

Electric Welding Glossary

The following are common electric welding terms:

AC (Alternating Current) - AC is common household current. AC stick and AC wire feed welding is least desirable because the arc is very erratic and unstable due to the current switching from positive to negative. However, it is the least expensive welding arc to purchase.
CC (Constant-Current Welding Machine) – These welding machines have limited short circuit current. They have a negative volt-amp curve and are often referred to as “droppers”. The voltage will change with different arc lengths while only slightly varying the amperage, thus the name constant current or variable voltage; used in Stick and TIG welders.
CV (Constant-Voltage, Constant-Potential (CP) Welding Machine) – “Potential” and “Voltage” are basically the same. This type of welding machine output maintains a relatively stable, consistent voltage regardless of the amperage output. It results in a relatively flat volt-amp curve (used in MIG and flux cored welders) as opposed to the drooping voltampcurve of a typical Stick (SMAW) welder.
DC (Direct Current) – DC is created by converting AC current into DC current. DC is the much preferred type of current to use for welding because the arc is very smooth and stable with minimal spatter of the filler metal.
Duty cycle – The duty cycle of a welder is the amount of time the welder is designed to operate in a ten minute period, i.e., 20% = two minutes. Duty cycle can be increased on some models up to 100% with decreased output. However, duty cycle is rarely an issue for customers.
Filler metal – Filler metal is metal from a stick or wire that is melted in the arc of the welder and combines with the metal being welded to form an alloy that binds the work pieces together.
Flux – Flux is a material included in a welding stick or fluxcored wire that gives off a gas when it burns. This gas serves to shield the welding arc. See shielding.
Shielding – The electric arc of a welder needs to be protected from the gases of the atmosphere in order to make a good weld. The gas either comes from burning flux (see flux) or from shielding gas (see shielding gas).
Shielding gas – Shielding gas is supplied directly from a gas cylinder and is required for wire welding with solid wire. The shielding gas is a mix of 75% Argon and 25% CO2 (C-25), 100% straight Argon for aluminum, and a mixture of Argon, CO2, and helium for stainless steel (also called “tri-mix”). These gases come in various cylinder sizes. See the Thoroughbred Industrial Cylinder Exchange section for specifics.
Stick – A stick is a metal electrode that also serves as the filler metal in the stick welding process. The shielding gas is obtained from flux in the electrode outer coating. See flux.

Oxygen-Acetylene Torch Outfit Basics

Torch outfits produce heat (energy) by burning acetylene gas. By adding oxygen gas, torch outfits can produce flame temperatures of 5,620 degrees. A torch outfit is extremely versatile: this single piece of equipment creates its own portable heat source and can be used to cut, heat, weld, and braze various metals. Before electricity was available in rural areas, this was the only type of "welder" available to the farming/ranching community.

The basic torch outfit consists of two high-pressure cylinders (one apiece for oxygen and acetylene) and two corresponding pressure regulators. A dualine hose transfers oxygen and acetylene from the regulators to the torch handle.

The torch handle can hold a cutting attachment, welding tip, or heating tip (the heating tip is not included with all basic torch outfits). If you are cutting with the torch, you also need a cutting tip that attaches to the end of the cutting attachment.

The cutting tip controls the thickness of metal being cut, along with the gas pressures set at the regulators.

All torch outfits that use oxygen and acetylene reach the same working temperature of 5,620 degrees. The size of the cylinder does not affect the temperature of the flame. It affects how long the flame will last (the burn time).

To get their projects done, you will need proper safety gear. Goggles (Minimum Shade #5) protects your eyes while you are using the torch. Welding gloves protect your hands. You will need a hand-held striker to create the spark to light the acetylene and a cylinder cart to hold the cylinders and accessories securely.

Types of Electric Welding

Stick Welding (SMAW or Shielded Metal Arc Welding)

Stick welding (also called SMAW or Shielded Metal Arc Welding) is the process of melting and joining metals by heating them with an arc between a covered metal electrode (rod/stick) and the workpiece. Shielding gas is obtained from the electrode outer coating (called flux).

The advantages of stick welding include:

Welds steel, stainless steel, cast iron, hard surfacing, and aluminum
The only electric process that can weld cast iron
Suited for windy, outdoor conditions
Can be used for welding on dirty or rusty metals with select filler metals
Economical
DC good for out-of-position welding.

The disadvantages of stick welding include:

Not good for metals thinner than 16 gauge
Tends to have more spatter than other processes

Wire Feed Welders / MIG Welding (Metal Inert Gas,also known as GMAW or Gas Metal Arc Welding)

The type of shielding gas depends
on the type of wire. For mild steel
wire, the gas is C25 (that is, 75%
Argon and 25% CO2) or CO2. For
aluminum wire, the gas is Argon.
For stainless steel wire, the gas is
called “tri-mix” (a mixture of
Argon, CO2 and helium).

MIG (Metal Inert Gas) Welding (also called GMAW or Gas Metal Arc Welding) joins metals by heating them with an arc between a continuously fed wire (filler metal electrode) and the workpiece. Externally supplied gas or gas mixtures provide shielding (available through the Thoroughbred Industrial Cylinder Exchange).

The advantages of MIG welding include:

Welds steel, stainless steel, and aluminum
Continuous wirefeed makes it the easiest process to learn
Produces cleaner welds than other processes
Can be used for high-speed welding
Provides good control on thinner metals
Good for out-of-position welding

The disadvantages of MIG welding include:

Must not be used in windy conditions
All paint and rust needs to be cleaned off the material before welding

Wire-feed welders such
as flux-cored and MIG
welders, work like a
caulking gun. When you
pull the trigger on the
gun, the wire feeds out
continuously until you
release the trigger or run
out of wire.

Flux Cored Arc Welding (FCAW) melts and joins metals by heating them with an arc between a continuous consumable electrode wire and the work.

The advantages of flux-cored welding include:

Continuous wirefeed makes it the easiest process to learn
Welds steel and stainless steel
Works well on dirty, paint, and rusty material
Good for out-of-position welding
Can be used in windy conditions
Has increased metal deposition rate
Provides deep penetration for welding thick sections

The disadvantages of flux-cored welding include

Requires slag removal after welding
Produces a lot of spatter that needs clean up after welding

TIG Welding (also called GTAW or Gas Tungsten Arc Welding) joins metals by heating them with an arc formed between the tungsten electrode and the base metal. (The tungsten electrode, unlike a stick electrode, does not become part of the completed weld). Filler metal is sometimes used and Argon inert gas or inert gas mixtures are used for shielding.

The advantages of TIG welding include

AC TIG welds aluminum and magnesium alloys
DC TIG welds brass, copper, steel, stainless steel, and titanium
Provides the highest quality and most precise welds
Ability to weld thin materials

The disadvantages of TIG welding include

Requires more skill and experience than any other method

Resistance spot welding (also called simply spot welding) joins two pieces of metal by passing current between electrodes positioned on opposite sides of the pieces to be welded. There is no arc with this process and it is the resistance of the metal to the current flow that causes the fusion.

The advantages of spot welding include:

Welds steel and stainless steel
Relatively easy to use
No shielding gas required

The disadvantages of spot welding include

Primarily used for sheet metal work

Types of Torch Outfit Processes

Cutting

Torch Process Fact
Cutting is the #1 most widely used
process of the gas torch outfit.

The cutting attachment hooks up to the torch handle and holds the cutting tip. By burning acetylene enriched by oxygen, the attachment and tip heat the metal to critical temperature. At this point, the cutting oxygen lever is depressed, delivering a stream of oxygen that cuts the metal.

The advantages of gas cutting:

It is portable (can be taken anywhere and used).
It is able to cut thick material with a range of cutting tips (sold separately).
It requires a low skill level and is easily mastered.

The disadvantages of gas cutting:

The oxygen-acetylene gas, once combined, will only cut iron-based (ferrous) steels.
The process can distort thin metals unless correct cutting tip is used.

Torch Process Fact
Heating is the #2 most widely used
process of the gas torch outfit.

The gas heating tip (also known as a rosebud or MFA) does not come with all basic torch outfits, but is sold separately at Tractor Supply. The heating tip attaches to the torch handle. The tip has multiple orifices (holes) that allow multiple flames to exit the tip. These flames can heat a large area of metal very quickly to allow bending or straightening.

The advantages of gas heating:

No other tool can heat metal so quickly.
It is portable (can be taken anywhere and used).
It requires a low skill level and is easily mastered.

The disadvantage of gas heating is that the heating tip uses a tremendous amount of oxygen-acetylene.

Torch Process Fact
Welding/fusion is the #3 most
widely used process of the gas
torch outfit.

The gas welding tip attaches to the torch handle. The flame heats the base metal to its fluid or puddle state. At this point, the gas welding rod (copper coated steel) is dipped into the puddle. The rod fuses to the base metal, creating the weld as they become one piece of metal. The steel welding rod must match the steel base metal in order for true fusion to occur.

The advantage of gas welding:

It is portable (can be taken anywhere and used).

The disadvantages of gas welding:

It is a two-handed process thatrequires a high skill level andtakes practice to master.
Only works on iron (ferrous)based steels.

Brazing (Adhesion)

Torch Process Fact
Brazing/adhesion is the #4 most
widely used process of the gas
torch outfit..

The gas welding tip attaches to the torch handle. The flame heats, but does not melt, the base metal. The flux-coated brass rods or bare rods dipped in brazing flux are then melted onto the heated base metal. The melted brass forms a bead on top of the base metal that holds the pieces together.

The advantages of gas brazing:

It is versatile (with the correctbrazing rod many differentmaterials can be brazed).
It is portable (can be takenanywhere and used).

The disadvantages of gas brazing:

It is a two-handed process thatrequires a high skill level andtakes practice to master.

See the Appendix for a table ofwhich metals to braze and which to weld.

What Type of Metal Do You Need?

Electric Welding

What type of metal do you want to weld? Different welding processes work for different types of metal. See chart below.

Metal Type	Welding Process

	Stick	MIG	Flux Wire	AC-TIG	DC-TIG	Resistance Spot
Steel	X	X	X		X	X
Stainless Steel	X	X	X		X	X
Aluminum	X	X		X
Cast Iron	X
Copper/Brass					X
Magnesium Alloys				X
Titanium					X

What thickness of metal do you want to cut with aplasma cutter? You will need a powerful enoughplasma cutter to cut the desired metal and thickness.

Maximum Cutting Depth	Air Force™ 250/250a	Air Force™ 400	Air Force™ 625

Steel	1/8"	3/8"	3/4"
Stainless Steel	1/16"	1/4"	1/2"
Aluminum	1/16"	1/4"	3/8"
Cast Iron	1/16"	1/4"	3/8"
Copper/Brass	1/16"	1/8"	3/8"
Magnesium Alloys	1/16"	3/16"	1/4"
Titanium	1/16"	1/8"	1/4"

What are your welding skills? Certain types of weldingrequire more skill than others.

Welding Process	Stick	MIG	Flux Wire	AC-TIG	DC-TIG	Resistance Spot

Skill Level	Moderate	Low	Low	High	High	Low

Where and in what conditions will you be welding?
For example, a process such as stick or flux-cored welding can be used in windy, outdoor conditions, while flux-cored welding is good for out-of-position work. Keep in mind the following guidelines:

Stick and flux-cored welding can be used safely outdoorsin windy conditions.
DC stick or wire feed welding is good for out-of-position welding.
Stick and flux-cored welding can be used with rusty, painted, and dirty metals.

Here are some things to consider before you decide which torch outfit best meets your needs:

Will this be a general purpose outfit or a portable "tote" set? Because of its portability, a tote outfit is perfect for a "beginner's outfit," a second portable set for a farmer/rancher, or for tradesmen such as plumbers and HVAC technicians.
A tote outfit comes with empty #1 size oxygen and acetylene cylinders. The oxygen and acetylene gas can be obtained through an exchange of the empty cylinders for full cylinders through the Thoroughbred Industrial Cylinder Exchange cage. When full, the #1 size cylinders will provide approximately 30 minutes of burn time.

Safety Note: The tote outfit can be used to cut, weld, and braze, but it should never be used with a heating tip (also known as a rosebud or MFA). These tips consume a tremendous amount of acetylene and will exceed the safe withdrawal rate for this size cylinder. (The standard is that only 1/7 the acetylene cylinder contents can be withdrawn from the cylinder over the period of one hour.)
For more heavy-duty applications, a general purpose outfit enables you to cut, heat (if the outfit comes with a heating tip),weld, and braze. These outfits are perfect for shop-type applications. However, these outfits do not come with oxygen acetylene cylinders or a cylinder cart. These general purpose outfits can be matched with three different sizes of acetylene cylinders and four different sizes of oxygen. The larger cylinders provide longer burn times. See the Thoroughbred Industrial Cylinder Exchange Cylinder Size Options section for more information.

The Thoroughbred Industrial Cylinder Exchange

The Thoroughbred ("T-Bred") Industrial Cylinder Exchange, available through Tractor Supply Company, provides oxygen, acetylene, and Argon/CO2 cylinders for all uses, from homeowners and hobbyists, to farmers and contractors. Just visit your local TractorSupply store to:

Purchase a filled T-Bred cylinder (contents and cylinder)
Exchange an empty customer-owned cylinder for a filled T-Bred cylinder

T-Bred does not lease or rent cylinders or accept leased or rented cylinders for exchange. Customers must sign the “Customer Ownership Acknowledgement Form” in order to participate in the exchange.

The burn times and other specifications for cylinder sizes 2-4 are listed below.

Cylinder Size #2

Burn time: approximately one hour

Acetylene #2
40 Cubic Feet (also called a "B" tank)
Male thread, CGA 520 valve
Oxygen #2
40 Cubic Feet
Male thread, CGA 540 valve

Note: Acetylene Cylinder #2 has a male threaded CGA 520 Valve. The acetylene regulator has a male threaded CGA 510 inlet. A TB-317 female/female adaptor must be purchased for assembly.

Cylinder Size #3

Burn time: approximately one-and one-half hours

Acetylene #3
75 cubic feet
Female thread, CGA 510 valve
Oxygen #3
80 cubic feet
Male thread, CGA 540 valve

Note: All #3, #4, #5 cylinders (full orempty) must have their cylinder capsin place at all times.

Cylinder Size #4

Burn time: approximately two hours

Acetylene #4
145 cubic feet
Female thread, CGA 510 valve
Oxygen #4
125 cubic feet
Male Thread, CGA 540 valve
Oxygen #5*
251 cubic feet
Male Thread, CGA 540 valve
Four hours of burn time

Note: All #3, #4, #5 cylinders (full or empty) must have their cylinder caps in place at all times.

*Can be matched with the #4 acetylene providing four hours of burn time

Frequently Asked Questions (FAQ)

What materials can be welded with a stick welder?
You can weld mild steel, stainless steel, cast iron, hard surfacing, and aluminum
What are the advantages of an AC stick welder?
- An AC stick welder is versatile and economical
- It welds thick materials (3/8”-1/2”)
- It is easy to change electrodes for different base metals
- It welds cast iron and hard surfacing
- It can cut and gouge
What is the advantage of an AC/DC stick welder?
The AC/DC welder has the same advantages as AC welder, plus DC for better control of the arc and minimal spatter.
What is the disadvantage of stick welding?
- It’s too hot for thin materials
- It can’t adjust to lower amperages for thinner materials
- It is limited to materials over 1/16” thick
What is the advantage of a wire feed welder such asMIG or flux-cored?
- It is able to weld thinner materials (24 gauge — 24/1000”— with select models)
- It reduces spatter
- There is no slag left on weld for reduced clean up
- It is versatile, especially the 115 volt models
- It can weld with stainless and aluminum wires
What is the advantage of the flux cored weldingprocess?
- You are able to weld in windy conditions where shieldinggas would be blown away.
- It is deep penetrating similar to a 6011 stick electrode.
What is the spool gun used for?
The gun is used mainly with aluminum wire because the feed length for the wire is less than six” compared to ten ft with a MIG welding gun. The spool gun reduces the feeding problems with soft aluminum wires. It also can be used with other wires(solid and flux cored) where the 20 ft. length is an advantage.
What is the advantage of stick welding compared to wire feed welding?
- It is economical for thicker mild steel materials (3/8”-1/2”)
- You have easy electrode change over for different base metals
- A wider variety of materials can be welded
- It is available in AC and DC models
- Gives you the ability to weld cast iron
- Many hard surfacing rods are readily available
What is the advantage of continuous wire feed welding compared to stick welding?
- Easier to operate (like a hot glue gun)
- You can weld thinner materials
- You can use solid and flux cored wires
- Makes it easier to weld aluminum
- Can be used with spool guns
What is the advantage of a welder/generator over a standard stick welder?
It is portable and can be used as a generator.
What materials can a plasma cutter cut?
A plasma cutter can cut any electrically conductive material, including steel, stainless, aluminum, copper, brass, and galvanized metal.
How does a plasma cutter differ from an oxy-acetylene cutting torch?
A plasma cutter uses electrical arc and compressed air to cut VS heat from burning gases. It also uses electricity rather than oxygen and acetylene. Plasma cuts all electrically conductive materials where oxy-acetylene is limited to ferrous materials.
What is the advantage of a TIG welder?
- It is a stick and TIG welder in one
- It can weld thinner gauge aluminum, copper, brass, stainless steel, steel and titanium
- It provides a superior weld bead appearance.
What's the difference between gas welding and gas brazing?
- Gas welding is fusion, where the steel welding rod actually melts with the steel base metal to become one piece of metal.
- Gas brazing is actually adhesion, as the final bond is between two distinct pieces of metal. Once the base metal is heated, the brass filler rod is deposited on top of the base metal and the two pieces adhere or stick together.
How long does this set of cylinders burn?
- With a 0 cutting tip and 1/2-inch steel, standard burn times are as follows:
  - Size # 1: 30 minutes
  - Size # 2: One hour
  - Size # 3: One-and-one-half hours
  - Size # 4: Two hours
Can I rent or lease a cylinder through this program?
- T-Bred does not lease or rent cylinders, or accept leased or rented cylinders for exchange. Customers verify ownership of the trade-in cylinders in order to participate in the exchange by signing the “Customer Ownership Acknowledgement Form.”
Are these cylinders safe?
- All cylinders in the T-Bred program are approved by the Department of Transportation (DOT).
How much do these cylinders weigh?
- Full Thoroughbred cylinders vary from 8.5 to 82 pounds when full. Consult the Thoroughbred Industrial Cylinder Exchange brochure for information on the weights of all cylinders offered through the program.

Appendix: Oxygen Acetylene Welding and Brazing Specifics Chart

Consult the chart below for which base metals can be joined by brazing (adhesion) and which by welding (fusion).

Metal Type	Process	Welding Rod

Steel	Welding	Copper coated steel rod
Steel	Welding	Flux coated or bare brass rod
Cast Iron	Welding	Flux coated or bare brass rod
Galvanized Steel	Welding	Flux coated or bare brass rod
Brass	Welding	Flux coated or bare brass rod
Copper	Welding	Flux coated or bare brass rod
Copper	Welding	Self fluxing copper alloy rod
Aluminum/Magnesium	Welding	Self fluxing aluminum/magnesium rod

For more information about welding, call or visit your local Tractor Supply store today!

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