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Arc welding vs gas welding

by Hassan Moore

There are many types and classifications of welding techniques and processes you will found, and instead of helping, you get confused about which one is suitable for you and your welding project.

Primarily, there are only a few types of welding processes, and the rest of them are taken from them. Among all, the most common and most used types of welding are arc welding and gas welding.

Arc welding and gas welding are being used for years, and over time, they are getting advanced.

To help in choosing the best welding method, you need to know the fundamental difference between them, and therefore, to address this issue, here in this article, we are going to talk about arc welding vs. gas welding briefly.

ARC WELDING VS GAS WELDING

An Overview of Arc Welding

Arc welding is one of the long-established forms of welding process and yet still popular among welders. Arc welding, to weld pieces of metals together, utilizes an electrical arc.

An electrical arc is generated by an electric power supply, and when it heats to a specific temperature, it melts down the electrodes or the base material to weld the joining points.

When an electrode starts to melt, it forms a shielding gas when combined with the oxygen from the environment; it protects not only the arc but also the welding area. When a melted pool cools down, it binds the metal together.

Arc welding can further be divided mainly into two types. The one is which uses the consumable electrodes, and the other one that uses the non-consumable electrodes. Other than the electrodes, arc welding can be done using the AC and DC current.

Arc welding is a manual process; moreover, it can be changed into a semi-automatic or fully automatic function with additional tools and equipment.

Mainly, the kit required for arc welding includes a power supply machine, welding rods, cables, clamps, and electrode holders. Domestic current works well with arc welding.

Other than that, the safety of a welder is most important, and for this, you need to have a complete set of personal protective equipment. Do not perform a welding process if you do not have a welding helmet, gloves, and eye protection glasses.

As arc welding produces high heat intensity, it is mainly used for thicker materials and heavy projects. From the construction of bridges to aircraft maintenance, the use of arc welding can be seen all over.

In addition to the high level of heat intensity, arc welding gives you high speed and as well as efficiency and quality weld.

When compared to other types of welding, arc welding pieces of equipment are readily available at an affordable price and easy to move from one place to another.

On the other hand, there are a few drawbacks to using the arc welding system. Firstly, it is not preferred for thin materials, as it can melt the material due to the high-intensity heat level.

Arc welding requires changing of electrodes from time to time, and it takes time and effort to do it in a proper way. Besides that, slag is produced, and therefore, finishing is required at the end.

An Overview of Gas Welding

Gas welding is a form of welding process that uses fuel gas to weld the materials. The flame torch is generated using a fuel gas with oxygen. The flame is then used to melt the filler material and the welding pieces; once it cools down, it binds the material.

The use of gas welding is mainly carried out where the reach of electric power is not possible or complex such as in underwater or remote places.

Gas welding is as much practical and effective as any other type of welding. It is a preferred choice for many industries and trades because of low-cost equipment and labor.

Different fuel gases are being used for gas welding, and when combined with oxygen, it creates a flame that can reach to a certain level of temperature.

The choice of fuel gas, therefore, depends on the heat intensity required on the basis of the particular welding project. Among all other fuel gases, the most common are acetylene and gasoline.

Gas welding requires you to have a separate chamber or tank in which oxygen and fuel gas can be mixed; other than that, it requires a welding torch and control valves to regulate the intensity of the flame. It is necessary to take care of the ratio of oxygen to the fuel gas.

One of the main benefits of gas welding is that it requires no electricity, and the equipment cost is also relatively low and is extremely portable. Besides that, it is easier to learn and practice.

Above all, with gas welding, you can weld ferrous and non-ferrous metals easily.

Summary

Both arc welding and gas welding are quite effective and reliable ways of welding, but there are a few limitations that come with gas welding.

No matter what fuel gas you may use, it cannot reach to the temperature, which can be achieved by arc welding; this makes the gas welding not suitable for thick materials or high strength steel.

In addition, the gas welding takes time to fully reach to the required temperature; this makes the whole process slower as compared to arc welding.

As far as safety and well-being are concerned, it is very important that you must take care of it whether using arc welding or gas welding.

The probability of risk remains the same in all types of welding, and therefore you should not proceed with the welding process until and unless you wear personal protective equipment.

To be more specific, gas welding requires you to take additional safety measures such as safety of gas cylinders, ensuring there is no leakage of fuel gas and exposure to the chemical.

Proper ventilation is required, and you should not use the gas welding equipment for a more extended period of time.

If you take care of the safety protocols and follow the standard procedure, you will be able to perform the welding process smoothly and effectively, whether you are using gas welding or arc welding.

Ultrasonic welding vs heat staking

by Hassan Moore

As the world is rapidly moving toward advancement and technology, welding is one of many fields that has seen a rapid change in techniques and conventional methods.

Advanced welding approaches are now being developed and taking over the old versions.

One form of advanced welding is known as ultrasonic welding, and it is increasingly becoming popular day by day.

When it comes to welding, many of us think of it as a way to join two or more materials together, especially the metal pieces, and we often relate it with heat staking.

However, there is a clear difference in both, and both of these methods are used for specific purposes. This article will highlight the important aspects of ultrasonic welding vs heat staking to clear the misconceptions between the two.

By going through the article, you will be able to clearly define the differences between the two and will know the specific purpose of each.

ULTRASONIC WELDING VS HEAT STAKING

Ultrasonic welding

Ultrasonic welding is the fastest growing technology in the field of welding. Ultrasonic welding uses mechanical vibrations at very high frequencies that are above the audible range of a human being.

Ultrasonic welding is largely being used to weld plastics and different metals.

The mechanical vibrations generate heat, and as a result, the edge of joining pieces melts and fuse together to form a bond.

The rate of production with ultrasonic welding is much higher with accurateness and preciseness as compared to other forms of welding, and therefore it is well matched for mass production.

Ultrasonic welding machine equipment mainly consists of a power supply, transducer, booster, horn and clamping devices.

The components that need to be weld are put together and held under pressure with clamping devices.

The power supply generates a high current, which passes through the transducer. The job of the transducer is to convert the electrical current to mechanical vibrations.

The vibrations are then sent to the booster to further increasing the frequency; after that, it is forwarded to the horn linked with the welding plate.

Pressure is applied through the clamps and welding plates while the horn supplies the vibrations. As a result of it, the temperature rises due to which deformation at the interface take place and form a joint.

There are many advantages of using ultrasonic welding over other types of welding processes.

Ultrasonic welding is much faster among all other forms of welding; within a fraction of seconds, it can do the work; in addition, the whole process of it can be converted to full automation.

Ultrasonic welding is highly reliable and effective; it possesses less health risk and does not create a slag or leftover, as it does not require any bonding agent or external heat. It is a clean welding process.

Thus, it requires very less or no finishing work. Above all, Ultrasonic welding is eco and user friendly as compared to other types of welding techniques.

The benefits of ultrasonic welding make it a preferred choice for various industries. From automotive to aerospace and from medical to packaging, the use of ultrasonic welding is everywhere and increasing with time.

In short, ultrasonic welding is versatile and is being used in many different industries and trades for different purposes.

Heat staking

Heat staking is a technique that is mainly used to join two similar or dissimilar materials or pieces together. It works by raising the temperature of joining materials and then reforming it to make a bond.

Heat staking works on plastic and as well as on metals, and it also allows you to link plastic with other types of materials that are not likely to be happen with welding.

Usually, heat staking is applied on the plastic materials, one of which contains a hole and the other has a boss. A boss, in mechanical terms, is a shape of an object that fits in another material containing a particular hole.

Heat staking is also referred to as thermoplastic staking. It does not need screws and nuts; rather, the joint created through heat skating is strong and reliable.

Heat staking has versatile uses and is being used by many industries and trades, including automotive, electronics, and information technology. The other applications of it include sealing holes, bonding, and welding.

Unlike welding, it does not require huge machinery or tools, does not produce slag, and the task can be achieved in few seconds.

No mechanical vibration is formed during the process of heat skating, and thus, no damage is caused to the object, while in ultrasonic welding, high frequency vibration can cause defects in material.

The same goes with pressure; heat staking does not put much pressure or stress on the material, whereas in ultrasonic welding, it is an essential component of a whole process.

The equipment and processing cost of heat staking is much lower than ultrasonic welding, and one important thing is that for ultrasonic welding, you require a set of skill and knowledge, while for heat skating, you do not need to be an expert in the field.

No extra material or adhesive is required for heat skating, and despite of that, it offers excellent durability, as much as you can achieve with ultrasonic welding.

Furthermore, maintenance and repairing heat staking is much easier as compared to ultrasonic welding.

Conclusion
Now you are well aware of the working of both the processes and knows the basic difference in between.

The choice of selecting an appropriate method mainly depends on the type of base material, the budget you have, ease of use and any other particular needs and requirements.

You should go for the method in which you are more comfortable and have the required knowledge and expertise.

Once you have read the article completely, you will not only be able to differentiate between ultrasonic welding and heating staking, but it will also help you in choosing the best suitable method for you.

At the end of the day, it is the efficiency and the reliability that matter the most, and based on the information provided above in the article, both of the techniques are highly efficient in their own way.

Auto darkening welding helmet vs passive

by Hassan Moore

A welding helmet is among the most fundamental safety gear; it is something you cannot overlook while performing a welding process.

When it comes to choosing the best welding helmet, welders get confused as a wide variety of helmets are available with different specs, features and qualities.

Typically, good-quality welding helmets are divided into two categories, auto darkening welding helmets, and passive welding helmets.

Although there is a very clear difference in features and qualities of both the helmets, people still find it hard to distinguish between both the types and fail to choose the best one.

For that reason, here we are going to present you with a comprehensive view of auto darkening welding helmet vs. passive welding helmets, and after going through it, you will be able to identify the best suitable option for you, and it will become easier for you to differentiate between them both.

AUTO DARKENING WELDING HELMET VS PASSIVE

Auto darkening welding helmet

A welding helmet is a safety gear, which not only protects your face and head but also it gives protection to the eyes. Eyes need to be protected at all times during the welding process.

When we talk about eye protection, the one thing that comes to mind is the quality of the lenses used in a welding helmet. Lenses determine whether a helmet is useful for the protection of the eyes or not.

Auto darkening welding helmet, as clear by the name, comes with advanced lenses technology by which it can automatically turn dark or light depending on the light around it.

It can automatically adjust itself to filter light at different concentrations and intensities.

When it comes to the welding process, the lenses of auto darkening welding helmet get dark when an arc is generated, and it gets clear when you turn off the arc.

In this way, it will not only saves your time to manually turning the lenses but also protects you from the effects of accidental spark lighting.

It can be seen from here that auto darkening welding helmets are convenient and effective, and you will not require to put your helmet on and off to see your work.

Wearing auto darkening helmet, you do not need to remove your helmet, as you will get a clear view of everything during and after the welding work.

The use of auto darkening welding helmet will ultimately increase productivity as the welder will be more focused on work and will not need to set the helmet over and over again.

also makes the welder feel more comfortable and relaxed. Other than the production, accuracy, and preciseness in work will also be enhanced.

Let us see the snap of advantages and disadvantages of having an auto darkening welding helmet; it will give us a clear view of the differences and will help us in deciding the best helmet for us.

Pros
  • Enhanced performance and stability
  • Saves time
  • Better protection and comfortability
  • Automatic shade control
  • Allow better control of welding tools and the process
Cons
  • Expensive
  • Heavyweight
  • A limited number of shades

 

Passive welding helmets

Passive welding helmets offer great eye protection and give you a clear vision and view.  A passive welding helmet contains a standard glass viewing lens; however, it does not change dark or light as auto darkening helmet can do.

Passive welding helmets do offer UV rays protection and are comfortable and lightweight. When performing a welding process, you may need to lift and nod the passive helmet several times, which is an uncomfortable experience.

In a passive welding helmet, lenses can be easily replaced or changed as per your requirement, but when doing work, it takes a lot of your time and requires effort.

Unlike auto darkening welding helmets, a passive helmet does not require batteries or any additional thing to work and operate. In terms of cost, passive helmets are cheaper and are easily available.

Here is a quick synopsis of the benefits and the drawbacks of having a passive welding helmet.

Pros
  • Clear optical view
  • Lightweight
  • Greater user comfort
  • Cheaper and easily available
  • No batteries required
  • Replacing the lenses is simple
  • Easy to repair and fix
Cons
  • Not suitable for all types of welding work
  • Requires continuous manual adjustment

 

Summary

Now you are aware of the working conditions, benefits, and downsides of auto darkening and passive welding helmets.

It can be clearly seen that auto darkening helmets contain more features and add value to the comfortability of a welder.

Having said that, the price of auto darkening helmets is much higher as compared to welding helmets and are also much heavier in weight.

One main thing about the auto darkening helmet is that it needs to be powered either by batteries or solar, while a passive helmet does not require any of it.

When it comes to repairing or replacing a part, passive helmets are better as the parts are easily available, cheap, and easy to replace. In contrast, the parts of auto darkening helmets are expensive and are difficult to replace.

Although passive helmet offers a clear optical view, auto darkening helmet is not any less. The auto darkening helmet also gives a crystal clear view of everything, even when an arc is generated.

One important thing to notice here is that if you are a beginner, you are going to face a lot of problems and difficulties with a passive helmet, while on the other hand, auto darkening welding helmet will make your work a lot easier.

No doubt, using auto darkening helmet increases overall work performance, as the welder will be more focused on his work and will not require manual adjustment; it will also save the welder from neck pain or injury.

Use of auto darkening welding helmet allows you to work in close working space, as you will not require to set the helmet again and again.

Conclusion
Safety is essential, no matter what type of welding work you are going to perform, and when it comes to selecting a welding helmet, this article gives you a clear outline of auto darkening vs. passive welding helmet.
As soon as you are clear with the differences, then on the basis of cost, power source, and the type of welding work you are going to do, you can choose the appropriate welding helmet.

Welding oxygen vs medical oxygen

by Hassan Moore

Everyone is aware of the term oxygen, as it something that we breathe in. Human life does not exist in the absence of oxygen gas, but then, is it the only use of oxygen gas?

Of course not, we all have seen many different uses of oxygen gas at different places, and that includes in the welding process.

How come it is possible? What is the thing that differentiates between welding oxygen and medical oxygen? These are some of the questions that come into our minds, and we try to look for the correct answers.

At last, your search ends here as in this article we are going to talk about welding oxygen vs. medical oxygen, and after you know the basic difference of it, you will be able to clearly identify the uses of oxygen gas.

Before discussing the differences, first of all, let us see a brief overview of oxygen gas in particular.

WELDING OXYGEN VS MEDICAL OXYGEN

Oxygen

Oxygen is a colorless gas present in the air. The air contains approximately 20% oxygen, and the rest of it is a mixture of other different gases, including carbon dioxide.

Naturally, the oxygen is produced by the plants, the plants consume carbon dioxide from the air, and in return, they supply oxygen to the atmosphere.

We all know that oxygen is essential for human beings, and therefore, it has also been produced clinically. Mainly, the air liquefaction process is used for this purpose.

This method of obtaining oxygen involves the distillation of liquid air. First, you turn the air into liquid form, and then you warm it slowly; in this way, oxygen and other gases split up because of different boiling points, and then you process out the oxygen elements.

However, as time passes, there are certainly other new methods being developed to produce oxygen gas commercially.

The question arises here that is it the production method that creates a difference in medical oxygen and industrial oxygen. The answer to this question is no; the same oxygen is being developed no matter what method you use.

So what makes the difference in oxygen? Continue reading the article, and you will find the answer.

The difference between welding oxygen and medical oxygen

Oxygen grade

To put it into simple words, it is the grade of the oxygen gas that determines whether it is feasible to use for medical or for industrial purposes.

Compressed Gas Association (CGA) has classified the oxygen into seven different grades from A to G. Grades have been assigned on the basis of the level of purity. A grade being the least pure, i.e., 99.0% oxygen presence in a cylinder.

The oxygen is then further gets labeled by The United States Pharmacopoeia (USP). It is a body that tells that which oxygen should be used for medical purpose and which one can be used for welding.

As far as the grade for medical oxygen is concerned, it should be at least 99.5% pure, while on the other hand, the grade for welding oxygen should have 99.2%.

Filling in the cylinders

There is one more important thing that differentiates between the welding oxygen and the medical oxygen, and that is how they are filled in the cylinders.

Whenever you go for refilling the oxygen cylinder, they will ask you the purpose you will use it for. If it is being used for medical purposes, the mechanic will first evacuate the tank and then refill it with 99.5% pure oxygen.

For welding oxygen cylinders, the tank will be checked for the presence of acetylene, and if it is found, the cylinder needs to be cleaned first, and then your tank will be refilled.

Other than that, medical oxygen requires certification, and the same goes with the oxygen cylinder.

It is necessary to make sure that no impurities are found above a certain level for medical oxygen, not even added in by the cylinder itself. The welding oxygen tank, on the other hand, may not require certification for the cylinder.

In short, we can say that medical oxygen cylinders need to be evacuated and cleaned each time they are refilled, while it is not necessary for welding oxygen cylinders.

The price of the oxygen is also determined by the factor that how much pure it is and in which cylinder it is filled. The medical oxygen in this way will be a little bit more costly than the welding oxygen cylinder.

Conclusion
To put it into short, it is the level of purity that determines which oxygen is suitable for medical purposes and which can be used for other trades. Secondly, medical oxygen cylinders are treated and refilled with more care and attention, and it is necessary to make sure that impurities are not added into it in any way.

 

Frequently Asked Questions

 

What are the different types of oxygen?

Mainly, there are four types of oxygen gas, and that is aviation, medical, welding, and research. Each type is being used for particular reasons.

Is oxygen gas flammable or explosive?

Oxygen itself is not flammable or explosive, but it helps other fuels in burning more rapidly.

What are some uses of medical oxygen?

Medical oxygen is mainly used for life support, anesthetics and therapy.

What are important safety guidelines for medical oxygen?

Medical oxygen cylinder should be kept in an upright position and keep it away from any type of heat source. Do not light a matchstick or spark a flame when oxygen is in use in the room.

Does medical oxygen have an expiry date?

Medical oxygen cylinder can be used for three years, and after that, it needs to be refilled. Do not use an oxygen cylinder without a Doctor’s prescription.

What is the major role of oxygen in welding?

Oxygen gas is used in welding mainly because it helps in increasing the heat intensity and temperature. It becomes necessary when you are dealing with hard-core metal materials.

Is welding oxygen safe for breathing?

Industrial or welding oxygen does not contain any harmful substance; even then, it is not preferred for breathing.

Welding Rod 6011 Vs 6013

by Hassan Moore

As we already know that, there are many different types of welding processes and techniques being used for diverse purposes.

No matter which method of welding process you use, there is something that is used in all processes, and that is a welding rod.

A welding rod is an essential component to perform any type of welding process. The welding rod is often known as the electrodes or the filler material.

Generally, there are two types of welding rods or electrodes. One is known as the consumable electrode, and the other is known as the non-consumable electrode.

Consumable electrode, as the name defines, are the one, which melts itself in order to weld the metal pieces together. While on the other hand, non-consumable electrodes are the one that does not consumes or melt itself to weld metal.

WELDING ROD 6011 VS 6013

The welding rods are further divided into several types and based on factors such as base metal properties, thickness, position, and environmental conditions, they are being used for specific purposes.

The most well-known and commonly used welding rod types are 6011 and 6013.

This article will help you in differentiating in between welding rod 6011 and welding rod 6013 clearly.

The general idea of welding rod 6011

6011 rod is one of the most common rods you will found as it can be used for general repairing work and fabrication.

Despite of the welder position and other welding setups, welding rod 6011 is used primarily where deep penetration is required. Mainly, these rods are used by pipefitters and boilermakers.

You can use it to weld rusted or painted metals as well. 6011 rod can be used in both vertical and horizontal positions.

As far as polarity is concerned, 6011 has the capability to be run on AC and as well as on DC polarity.

Above all, you do not need any special treatment for storing the 6011 welding rod, it can be stored at room temperature, and it will not be affected in any way; you can carry or use it whenever you want.

One noticeable downside of using the 6011 welding rod is that it produces rough beads. Besides that, 6011-rod are not preferred to be used for stainless steel or non-ferrous metals.

One of the important factors in determining the quality of a rod is by checking its tensile strength. Tensile strength is the measurement of strength or forces a material can withhold without breaking.

The tensile strength of a welding rod is shown by the first two digits of a code. In the case of the 6011 welding rod, the tensile strength of this rod is said to be 60,000 psi.

The general idea of welding rod 6013

The 6013 welding rod is also used for general purposes. Typically, it is made of mild steel and is used primarily where medium-level penetration is required.

From general fabrication work to shipbuilding, 6013 electrodes are used widely for many different purposes.

Same as 6011, 6013 welding rod can also be used on AC and DC current source and can be used in all positions.

One main advantage of it is that it gives you smooth operation, optimum performance, and produces minimal beads.

When we talk about the tensile strength, as we know that it is determined by the first two digits, in the case of the 6013 welding rod, the tensile strength of this rod is the same as of the 6011 welding rod, i.e., 60,000 psi.

Summary

Based on the information provides, it can be said that 6011 and 6013 welding rod perfect in their own capabilities and plays a vital role in overall quality and reliability of welding materials.

The use of these electrodes is based on their properties.

Polarity and tensile strength of 6011 and 6013 welding rods are identical, however, as mentioned here, the 6011 welding rod offers deep penetration and is good to be used on rusty metals or lubricious surfaces, and when deep penetration is not required, 6013 rod is more suitable.

It is clear from the description that what are the major differences between 6011 and 6013 welding rods and which welding rod you should use depends on the needs and requirements of the particular welding project.

 

Frequently Asked Questions

 

Can you weld cast iron with 6011 rods?

Yes, 6011 welding rod can weld cast iron.

What are the most common electrodes?

There are hundreds of electrodes available in the market; however, according to the American Welding Society (AWS), the most common electrodes include E6011, E6013, E7014, E7024, and E7018 welding rods.

What do numbers represent in welding rods?

The first two digits of a number in a welding rod tell you about the tensile strength of a rod. It is specified in thousands. For example, the 6011 welding rod has a tensile strength of 60,000 psi.

The third digit indicates the position in which a rod is best suited for. For example, the 6011 welding rod has a third digit, “1”; if it is 1, it means that it can be used in all positions.

While, on the other hand, if the third digit is “2”, it means that it is only fit for flat welds.

The last two digits combine tells you about the type of flux coating a rod has on it. A flux coating is something, which tells you that what kind of current can be used with this specific rod. If the last two digits are “11”, it certifies that this welding rod can be used for any type of current.

The letter E with the number stands for electrodes.

In order to get the perfect welding experience, this should must match with the current you are supplying during the welding process.

How do I choose a welding rod?

Available power source, position, and base metal properties are the main factors you need to see when choosing an electrode for your welding project.

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ARC WELDING VS GAS WELDING

Arc welding vs gas welding

ULTRASONIC WELDING VS HEAT STAKING

Ultrasonic welding vs heat staking

AUTO DARKENING WELDING HELMET VS PASSIVE

Auto darkening welding helmet vs passive

WELDING OXYGEN VS MEDICAL OXYGEN

Welding oxygen vs medical oxygen

WELDING ROD 6011 VS 6013

Welding Rod 6011 Vs 6013

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