A Beginner's Introduction to Welding

I weld a brace onto a wheelbarrow, and use this example to discuss DIY welding techniques, including MIG welding, stick welding and oxyacetylene welding. Advantages and disadvantages of each technique are discussed.

[@billstmaxx]

that was one of the best instructional videos ive ever seen! thanks for posting!

[@spelunkerd]

There are few things more fascinating than having the opportunity to watch, as a puddle of metal melts into a useful device. It is close work, like any job involving staring at one spot, 12" away, for many minutes. And with everything else faded to black you don't have much of a visual frame of reference. But even when I worked on an assembly line I did not have a lot of eye strain. Most welds are short enough that you spend more time fitting pieces, as I did here.

[@spelunkerd]

For reasons of instability, acetylene in a small tank can not be allowed to discharge too quickly. If it does, the tank is at risk of explosion. So, if you want to use a really large torch head called a cherry blaster, get a larger tank that will safely permit higher flow. I installed back flow protectors for both tanks. It's a trade off of larger size and less mobility vs more versatility. Like the argon, I think it is more cost effective to fill larger tanks.

[@spelunkerd]

@donyboy73 I'm glad you asked that, because it emphasizes the biggest mistake I made when I set this up. This is a small tank, and if I were to do it again I would get at least a medium size tank. I chose to buy the tank, which I exchange through Praxair when empty. What I didn't know is that the refills for small tanks are almost as expensive as refills for larger tanks. So, it's much better to buy a big tank and refill less often. Gas is expensive....

[@spelunkerd]

It depends on the contract. Those who are subcontractors or self employed will supply gear, but those who work at a shop like I did will use the equipment supplied by the boss. Traditional welders (transformer design) are heavy, requiring a generator, 220V power, and a flat bed truck or trailer. Newer inverter TIG machines can run on 120V and are light enough to carry up a ladder. Most portable welding is done by stick, because it's more versatile in the wind compared to gas shielded techniques.

[@spelunkerd]

@jw200 Thank you. MIG welding is like pouring ice cream, sweet and smooth, easy, and usually giving a good result, especially with thin metal. But to tell you the truth, I prefer stick welding because it's more versatile, easier to work in wind, less expensive, and it gives better penetration for thicker metal.

[@Turbo231]

Very nice video, enjoyed it and loved the nice editing...nothing we didn't need. :) Makes it very easy to watch.

[@spelunkerd]

@donyboy73 I made both the cart for the welder and also the cart for the torch. Fun little weekend projects. I posted some of the intermediate steps for making those carts on flickr, using the same name (spelunkerd) as I use on youtube. Thanks for asking, Donny. Your small engine channel is the best on the web. It's great to see a fellow Canuck do well on the international scene.

[@spelunkerd]

Yeah, my ballpark numbers are 5 for acetylene and 30-35 for oxygen. But of course that depends on the size of your torch. The important point (one you likely already know, but I'll emphasize it for others) is that small tanks have a maximum discharge rate for acetylene. High acetylene discharge rates with a small tank can cause unstable and maybe even explosive complications. So, a cherry blaster isn't safely compatible with a small tank. Thanks for your feedback.

[@hp11208]

Cool video and good welding,your neighbor must be glad to have you as a neighnor lol.

[@dpjs22]

You're an awesome neighbor, i hope he bought you beer!

[@spelunkerd]

Yes, you're right. Even though static voltage may be OK, max output is poor with long runs. You can get 12 gauge cord, try for shorter than 20 feet if you can. The total run includes the run from your breaker panel. For must US citizens, they have 12 gauge wire inside the walls for garage circuits, but up here in Canada all the 120V wiring is standard at 14 gauge. Use a plug on a circuit that isn't already used for a lot of other things. Good luck!

[@spelunkerd]

@Iliketoweldandbraze Good point. I haven't done a lot of brazing, but whenever I weld with gas I wonder why I don't do it more often. Regarding the CO2, there's a good review in Wikipedia, "Shielding Gas". Heat transfer with pure Ar is poor, but when CO2 is added when welding Aluminum, the arc becomes unstable and there is lots of spatter and a bubbling, frothy, messy weld. Evidently CO2 is added with steel because it improves penetration and heat transfer. I'm not sure why the difference.

[@spelunkerd]

@Sidetracker Both are small. Small is more mobile and it may be less prone to suddenly losing a full tank if you have a leak. However the cost of refills is worth considering as well, with a refill for a medium or large tank being just a little more than refilling a small. Therefore there is economy of scale. Small acetylene tanks are not able to deliver large volumes that you might use for large heaters - high flow is dangerous with a small tank because of chemical instability.

[@donyboy73]

nice job on the carts!

[@spelunkerd]

@maxhauler You may be able to find something used on ebay or kijiji. Used professional equipment may offer a better duty cycle for less cash. New, the Lincoln 180 is about $650, and the gas with user-owned bottle is $250. I suggest getting a larger bottle since price is just a little more and gas is expensive to refill, about $80 per tank. Helmet is $50-150. You don't need a lot more, if you already have a torch and grinder. Always buy steel from a bulk wholesaler. Stick welding is cheaper!

[@spelunkerd]

@DiosdelTreno Yeah, it's an irony that professionals learn to do gas but almost never use it for welding, because it takes longer. I've used gas occasionally, most recently on a Sunday when I ran out of Argon. Works fine, almost like slow motion because the puddle takes longer to form. One day I'll take the time to do another video. For sure an oxyacetylene torch will be worth getting, because of versatility as a heating torch, a cutting device, and for brazing and welding.

[@spelunkerd]

Both of us recently moved, so we've both lost a good friend. Thanks for watching.

[@spelunkerd]

@DiosdelTreno I'm not finding that model on the Lincoln site, but as a guess I think it would be fine for a trailer. As you know, modern design for trailers use really thin steel for lightweight use, and there is very little steel over 1/4" thickness on my cargo trailer. The duty cycle is also a factor that separates professional from amateur equipment. That's not a big issue for most jobs, but you may need to take breaks if you exceed the duty cycle for your equipment.

[@spelunkerd]

I like my kit. However if I were to do it again I probably would look for a higher quality torch set -- the one I got was the best one sold at Princess Auto, and I had to rebuild it out of the box because it didn't work right. The O2 control is also too coarse, so a little tricky to adjust. Note that really high flow is not safe or possible with small tanks, so you may want a larger Acetylene tank to permit use of a cherry blaster. I made the frame myself. I want a TIG one day, too, ha ha.

[@spelunkerd]

These days, most metal devices are made of really thin metal, so power is not as important as it would be for thicker (>1/4") steel. Of course the answer depends on what you are using. The newer and more expensive inverter machines can run on 120V or 220V, but old transformer machines require 220V. If you want to weld aluminum, you need specialized MIG or TIG machines and pure Argon. My Lincoln 180 MIG is a versatile unit with enough power to do most projects. Duty cycle is also important.

[@spelunkerd]

@billstmaxx What a fine compliment. Thank you, Bill.

[@donyboy73]

all i need the torch is to cut the odd piece of metal and to heat parts for easy disassembly. i'm looking at a Victor torch set from linde

[@jw200]

Nice result. Very professional looking

[@spelunkerd]

Yes for welding with acetylene it is, cutting is different. I don't remember mentioning that during this video....

[@donyboy73]

nice vid, i may be getting the lincoln 180c next week

[@SeanCothrine1]

thank you so much for this informative video

[@Iliketoweldandbraze]

I did not know that about CO 2, it seems like I should have. You forgot to talk about my favorite method brazing.

[@spelunkerd]

I would rate it as at 7, but linear judgements are not complex enough. I would have liked a continuous voltage dial, not discontinuous stops for voltage, and I would have liked an LED with actual voltage displayed. Those are features of industrial machines, costing thousands more. Duty cycle is fine for what I do (usually thin metal, intermittent welding). The 180 comes with either a metal or a plastic wire driver, I would have liked the more durable metal one. At this price, it's great.

[@spelunkerd]

@donyboy73 I'm very happy with mine, though, using MIG, I miss the creative versatility of stick welding. I find it a little sad that most things are made of plastic now, and so steel welding has a smaller niche than it did when I started doing it a generation ago. With MIG you can buy an aluminum hand held spoolfeeder and 100% Ar to do aluminum. Aluminum wire is too flimsy to feed from the machine. Donny, I'm from Lethbridge, Alta, soon to move to Victoria.

[@donyboy73]

i'm thinking of getting a set of those oxy acet. torches, how do you like yours?

[@spelunkerd]

You want 75/25 Argon/CO2, it's fairly standard for welding steel. You can rent or buy -- I would buy, to save the rental fee every year. Get the largest bottle you can, since refill charge is about the same for a large or small. Then remember to turn the valve off at the tank every time. Yes, your 140 should handle that fine. You will want to give the machine frequent rests, so as to not exceed the duty cycle. Get some extra steel and practice to get the settings right.

[@donyboy73]

what size tank on the mig?

[@donyboy73]

nice setup, where did u get the cart? or did u make it

[@spelunkerd]

@DiosdelTreno This week, Jody at weldingtipsandtricks here on youtube did a great summary of safe procedures for using an oxyacetylene torch. Go to his channel and search cutting torch-tips. I wish I had learned this 40 years ago when I first started using a torch.

[@Lildream3]

What's a capable starting voltage for a new welder? Projects I hope to include are wheelbarrow fab from sheet metal(s), aluminum welding, dolly things like that.

[@CharisWilliams]

Nice work!

[@TheCogleymike]

Oh, I've also noticed power decreases when using extension cords. If I have the 140 plugged IMO my garage outlet 120v and I'm welding in my driveway about 10-15 feet away, what's a good extension cord gauge to use? Bigger the better I assume.

[@spelunkerd]

There are many factors that change the requirement for gas, how much breeze there is in the room, how close you hold the cup, etc. The flow is measured in cubic feet per hour, cfh. 15-25 cfh would be fine as a starting point. However I suggest you play with the gauges, try 0 cfh and see what happens. Notice the porosity? Then go to 5, then 10 then 15. Get lots of metal for practice, from a steel wholesaler, not a retailer. Have a look at videos by weldingtipsandtricks - he's great.

[@jacksonlee5189]

I am just starting to learn how to weld. I have an Everlast stick welder on order. Can a repair like this be done using stick welding?

[@alexmanning2755]

Hey there, quick question, im assuming this is steel that you are welding?

[@TheCogleymike]

Hey bud I have question. I have the lincoln 140 and its a sweet welder. I haven't yet hooked up a shielding gas bottle to it yet. And actually I have no idea what kind I should get or what I should do. I just have been welding motorcycle frame brackets and mower parts. I need to do some welding on my jeep frame rail that is 11 gauge. Think my 140 can handle it? It say I can set it at a D and 1.5 for wire speed. Any thoughts? Cheers

[@spelunkerd]

And thanks for the sub, nice to meet you. Dave

[@famasmaster2000]

Overall out of 10, how would you rate your 180? I am looking at one right now and so far most people have nothing but good to say for the price. Have you had any issues with yours? Thanks !

[@donyboy73]

@spelunkerd nice job on the carts, which province are you from, i'm from ontario

[@Solaniin]

i have a question, i understand that welders travel alot, do they carry their own equipment?

[@Sidetracker]

What size are the tanks of the oxygen/acetylene torch?

[@donyboy73]

@spelunkerd OK THANKS, I'LL GET THE ALUMINUM SPOOL GUN EVENTUALLY AND A SECOND TANK

[@TheCogleymike]

Ok thx buddy. I'll pick up some 75/25 tomorrow at a welding supply shop. I have many local. Any idea what I should turn the knobs too? Like psi? I have the DVD the welder came with. I bet it's in that. I'm not sure if more shielding gas is needed for thicker metal or its just an on/off situation. Cheers

[@ajadams5231]

cutting is 5 psi of acetylene and 40 psi of oxygen right

[@donyboy73]

@spelunkerd ok thanks

[@Yuna69able]

Will this strain my eyes at all?

[@vistron888]

I see there are also gas-less MIG welders. Pros/cons?

[@spelunkerd]

Flux core MIG wire allows you to use the welder outside where wind could blow the shielding gas away, allowing oxygen to get to the cooling steel, causing porosity. Welds with dual shield don't look quite as good, more spatter, similar to 6011 stick. Of course the wire is thicker because it has solid shielding components built into the wire, and your spool may need to swap over to a different size runner. In that setting I just switch to stick, which is cheaper and a little more mobile, and I don't have to switch rolls of wire over. There is also the process of dual shield welding, which uses both gas and shielded wire. I've never used dual shield, but I'm told that for deep penetration and faster workflow the dual shield can be better. Thanks for watching!

[@vistron888]

Thanks for the info!

[@ajadams5231]

I though acetylene was 4 psi for welding