Welding can be a useful skill for homeowners and DIYers. There are several types of welders available for different applications, including arc, MIG, TIG, and oxygen/acetylene. MIG and flux-core arc welders have become popular choices for homeowners as they produce clean welds and are relatively easy to learn. However, welding safety must always be followed by wearing protective gear like gloves and helmets. With practice, welding can be a fun and rewarding skill.

1. WELDING 101
A welder isn't usually the most sought after tool by many do-it-yourselfers. A welder can,
however, be a very handy and important tool for the contractor or those who want to
repair or build metal projects around the home. Welders are a necessity around the
farm and ranch, as well as for those doing auto repair work. Welding and welders may
seem daunting to the first timer and, indeed, welding can be challenging, requiring
learned skills. These days welding, however, isn't just for shop class nerds or
professional metalworkers; it can be fun, and any number of modern-day tools make
welding easier for even the first timer. Many modern welders are also less expensive
and don't require a special 220-volt circuit. Larger models do, however, require a 220-
volt circuit.
Types Available
Four basic welding tools and techniques are used: arc (stick), MIG, TIG and
oxygen/acetylene. Each welding technique has its advantages and disadvantages.
Stick welding has been the most popular method for most home-shop welding for a
long time. Stick welding uses an electric current flowing directly between a gap between
the metal and the “stick” or arc-welding electrode. The current causes part of the
electrode to melt, allowing it to mix with the metal of the work piece and form the weld.
The electrode has a flux coating that burns to form a protective shield around the arc.
Stick welding is the most effective method for welding many different alloys or joints.
Stick welding can be used outdoors or indoors or in drafty areas, is the most economical
method and will weld on rusty or dirty metals.
Stick welding does have some disadvantages. It is limited to metals no thinner than 18
gauge, requires frequent rod changing, has lots of splatter and the welds must be
cleaned up after they are finished. Stick welding is also more difficult to learn and use,
particularly in striking and holding the arc. Arc welders are available as either AC or DC
or AC/DC. AC welders are the most economical and are used for welding thicker metals
of 1⁄16 inch or more. They are the best choice for farmers, hobbyists, and home
maintenance chores. DC welders provide cleaner welds, fewer arc outages, less
splatter and sticking, and better control on thinner metals. They are also more
expensive.

2. Above: The traditional type of welding for homeowners has been arc or stick, but it
takes practice to strike the arc and hold it properly.
MIG welding (GMAW) (also sometimes called wire-feed) uses a wire welding electrode
on a spool that is fed automatically at a constant selected speed. The arc created by an
electrical current between the base metal and the welding wire melts the wire and joins
it with the base. This produces high-strength welds with a very good appearance and
little need for cleaning. MIG welding also uses a gas shield process with gas fed
through the welding torch and acting as a shield at the arc. This prevents oxidation and
contamination of the base metal. The gas utilized may be inert or active, depending on
the base metal to be welded. MIG welding is clean, easy and can be used on either thin
or thicker plate metals.
Above: Wire-feed welders feed a wire through a gun and are easy to use, produce clean
welds and many are now sized perfectly for homeowners.
A similar type of wire-feed welding is FCAW. It is slightly different from MIG welding in
that it does not require a shielding gas. This gas-free welding uses flux-cored welding
wire to shield the arc. This form of welding is the simplest, very efficient and extremely
effective, especially when welding outdoors in windy conditions.
Both MIG and FCAW are very easy to learn and can create super-clean welds on
steel, aluminum and stainless. MIG and FCAW weld materials as thin as 26 gauge.

3. Another form of welding is TIG, also called Heliarc. It utilizes tungsten inert-gas and is
used primarily by professionals.
Oxygen/acetylene welding utilizes oxygen and acetylene mixed at the torch to produce
a flame hot enough to melt metal. It can be used for metal cutting as well as welding
purposes. Oxygen/acetylene welding takes quite a bit of practice and skill, as well as
quite a bit of safety rules in storing and using the gases.
Safety
Welding, like many work procedures, can be dangerous if you don't follow safety rules.
1. Work in a safe area, free of all flammables, with both a fire extinguisher and a bucket
of sand available.
2. Exposure to a welding arc is extremely harmful to eyes and skin. Prolonged exposure
can cause blindness and burns. Never weld unless you are adequately protected. Wear
a heavy, long-sleeved shirt, cuffless pants, high-topped shoes, flameproof welding
gloves and a protective welding helmet.
3. Read and understand the welder's owner's manual.
Above: Auto-darkening helmets, like ArcOne, which we carry on our website, make it
easy to see the gun or stick placement but provide instant darkening.
Basic Practices
The following steps are the basics for MIG or arc welding. It's extremely important that
all metal surfaces to be joined are free of rust, dirt, scale, oil and paint. If the surfaces
are not properly cleaned, the weld can be porous and brittle. Remove oxidation and dirt
with a steel-bristled wire brush. Remove all oil or grease with a good cleaner.

4. The metal to be welded, as well as the ground-clamp area, must first be cleaned of rust, scale
and grease.
Aluminum requires even more preparation. First, use a good chemical aluminum
cleaner. Aluminum has an anodized surface and this must be wire brushed, sanded or
ground off the surfaces to be welded, as well as anywhere the ground clamp is to be
placed.
If joining thick metal pieces, they should first have their edges beveled with a metal
grinder. The angle of the bevel should be approximately 60 degrees at the point of
contact.
A variety of joints are used to fasten the metal pieces together. Below is a chart of the
most common joints.:
Connect the ground clamp to the work piece and as close as possible to the area to be
welded. On-board computer systems of automobiles can be damaged if the ground

5. clamp is connected directly. Do not weld until you have disconnected the cable from the
battery that is attached to the chassis ground.
When first learning to weld, it's a good idea to practice on scrap metal. Try different heat
settings, base metal thicknesses and welding positions for each type and size of wire
you will be using. Make sure you read and understand the owner's manual. Then turn
on the welder and follow the manufacturer's instructions on tuning in the wire speed and
heat settings.
Properly holding the gun is important for wire-feed welding. The gun can be held in two
basic methods, depending on the type of weld being made. Because the welding tip is
designed with the contact tip recessed from the end of the nozzle and the nozzle
electrically insulated from the rest of the gun, wire-feed welding is easy to learn. You
can actually rest the nozzle on the work piece and drag it along. This is very helpful for
beginners. Stick welding requires that you first touch the work to strike an arc, then lift
the electrode to prevent it from sticking and this takes some practice and skill.
Wire-feed welding is really quite simple. Line the gun up in the proper position on the
joint to be welded. Lower your helmet or hold up a welding shield and pull the trigger to
start the arc. In a second or two you'll notice a weld puddle beginning to form and the
base of the bead beginning to build. You can either push or pull the gun to move it along
the weld joint. When welding aluminum, it's best to push the gun as this creates a
cleaner appearance. Move the gun steadily and at the right speed to create a solid weld
without lumps or an uneven bead. This part does take some practice, but it's still easier
than stick welding.
The wire spool is first loaded into the welder and the wire fed through the gun.

6. The wire-feed rate and amp settings are then set to suit the material being welded.
Stick welding begins by first selecting the proper electrode. The electrode is basically a
rod coated with flux. The type and thickness of the metal and the position of the work
piece determines the electrode type and amount of heat needed.
Naturally, the thicker metals require more heat. Welding electrode and arc-welder
manufacturers provide selection charts as to the electrodes needed for specific chores.
You must next select the proper amperage for the electrode and the work piece. Turn
on the welder, set the amps, protect your eyes and strike the arc. It is akin to striking a
match, scratching the tip of the rod against the work surface, and then quickly lifting it to
the required 1⁄8-inch. This gap must then be maintained consistently during the welding
process. If the gap becomes too narrow the electrode will stick to the work surface. If
the gap becomes too wide the arc stops. At the same time you are maintaining the
proper distance, you must also maintain a consistent rate of travel with the rod along the
joint to create a proper bead. Too fast and the joint will be weak. Too slow and the bead
will overbuild with more slag. This does take practice, and it's best to practice on scrap
pieces.

7. Above: Arc or stick welding requires a bit more skill. The arc is made by scratching the
stick across the metal surface, then immediately lifting it and holding it 1/8" above the
surface.
Two types of beads are commonly used: stringer and weave. A stringer bead is created
by moving the gun in a fairly straight line and keeping the nozzle and wire centered on
the joint. This, naturally, is the easiest bead to make. A weave bed is used when you
must deposit metal over a wider space than with a stringer bead. This is made by
waving the gun nozzle side to side while moving along the weld.
Quite often, more than one bead is required to fill the V shape ground into the joint, as
well as to create a strong joint. If using a stick welder, or a self-shielding, flux-core wire
in a wire-feed welder, you must chip and brush the slag off each bead after it cools and
before making another pass. This slag must also be removed when the weld is finished.
Welders Available
Both stick and wire-feed welders are available in a wide range of sizes, rated by the
amperes they create. It's important to note the duty-cycle when purchasing a welder.
This is the percentage of actual weld time that can occur in a ten minute interval. For
example with a 20% duty cycle, actual welding can only occur for two minutes, and then
the machine must cool for eight minutes. Stick welders range from 50/70 amps up to
50/230 amps output. The smaller welders are 115 volt, the larger welders require a 220-
volt circuit. The smaller welders will handle materials up to 1⁄8-inch thick, while the
larger welders can weld steel up to 3⁄8 inch in one pass.

8. Wire-feed welders range from 30/70 up to 30/85 in 115-volt, 220-volt models up to 200
amps. Wire-feed models are available as flux-core or MIG. The former are the easiest to
operate as they require no gas. You can learn to weld in minutes. Many MIG units are
also available to weld with flux wire or with gas. This allows you to learn to weld the
easy way with the flux wire. Then simply add the gas bottle for more advanced welding.
A wide range of welders, including arc, MIG, TIG and oxygen/acetylene are available at
www.nhproequip.com.
Many welders come with a hand-held welding shield. If you do much welding you will
appreciate a welding helmet. Auto darkening models such as the ArcOne welding
helmets, make it easy to see the beginning placement of the gun or stick, yet instantly
darken to protect your eyes.
Don't be afraid to tackle welding. Today's tools make the chore easy for even a first-
timer, and you'll probably find it's fun and addictive.
-courtesty of www.extremehowto.com/