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- Welding

This page is the process for TRY "Welding".

In FabLab West-Harima, there is 2 welding machine (TIG and MIG). So, I plan to build a sturdy frame trestle out of steel material and welding for the flame base for MDX-40A (machine weight 66kg).

I designed the model, and Masuoka-san and I shared the role of welding.（Top side: Masuoka san, Bottom side: me）

1. Safety training

The founder of Fab Lab West-Harima has completed general welding training conducted by DAIHEN Corporation, I received safety training from the founder based on the safety training instruction manual.

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2. Protection

The following protection is required for welding.

  • Welding Helmet
  • Welding Work Mask
  • Welding gloves (Cow Leather)
  • Work clothes 100% cotton (long sleeves and long pants) alt text

3. Plan

alt text

4. Create model

Design by Fusion 360. The complete assembly is below. alt text Details of the part design are below.

Flame L: 2.3t x 60 x 60 x 800 alt text Flame M: 2.3t x 60 x 60 x 680 alt text Flame S: 2.3t x 60 x 60 x 420 alt text Steel Plate : 2.3t×60×60 R (Fillet 4.6)　 Confirmation of standard size of corner R of 2.3t thickness　　 alt text 3D model of Casters with adjuster (K-100AF) is got from MiSUMi. alt text

5. Data file

6. Prepare material

alt text

Title Shape Size (mm) Quantity Where to purchase
Panel (Top & Bottom) Steel Plate 2.3t x 800 x 800 2 MIKIKO steal
Flame L Square pipe　 2.3t x 60 x 60 x 800 4 MIKIKO steal
Flame M Square pipe　 2.3t x 60 x 60 x 680 4 MIKIKO steal
Flame S Square pipe　 2.3t x 60 x 60 x 420 4 MIKIKO steal
Steel Plate Steel Plate　 2.3t×60×60  R (Fillet 4.6)　 8 meviy(MiSUMi Service)
Casters with adjuster (K-100AF) 　 - 4 MiSUMi

NOTE: "Steel Plate 2.3t×60×60 mm (R: Fillet 4.6)", I purchased it by meviy.

meviy is MiSUMi's -service that allows users to quote and purchase sheet metal and cutting operations by uploading 3D data files. alt text

7. MIG

Machines I used
- SUZUKID ARCURY80 NOVA (100V, NO GAS) alt text

The items I used

  • Welding wire
  • Anti-spatter (Spa Block)
  • Anti Spatter Spray
  • Wire Brush

MAIN FROW

  1. Spray the material to be welded with an anti-spatter spray.
    alt text
  2. Apply anti-spatter adhesive to the tip of the torch

  3. Welder menu settings (set according to the prepared wire)
    In this time set below.
    　- 3-1)Select material, SYN(Fe)
    　- 3-2)Set welding wire diameter
    　- 3-3)Set the material thickness in 2.5 mm.
    alt text NOTE: After setting the material, wire diameter, and material thickness, the best welding voltage and welding current are automatically set.

  4. Attach grounding terminal (earth) of machine to material, then Welding. alt text

NOTE:
- Do not touch the material with bare hands after welding because the material is hot.
　 *After welding, scrape off excess dirt with a wire brush.
- Exposure of skin during welding is a cause of burns. The photo shows a bad example with the wrist is out. As pointed out from instructor, arm covers were worn to prevent arms from sticking out.

8. TIG

I learned The flow of TIG by weldtool.jp.
I practiced TIG welding, before the actual welding. It seems difficult, but just try. 　　

Machines I used:
- DAIHEN, INVERTER ELECON 300P
alt text

  1. Prepare
    1-1) Prepare machines, materials and welding rods
    1-2)　Torch Preparation　　 alt text 1-3) Attach grounding terminal (earth) of machine to material.
    1-4) Fix the threaded hose of the torch and put it on your shoulder.
    1-5) Ensure that the torch tip is at an angle that is easy to see while welding.
    1-6) Adjust the position of the switch (with the torch held naturally, the switch should be in a position where it can be pressed naturally)
    alt text

  2. Simulate before welding （image training)
    2-1)Direction of torch tip movement
    2-2) Where to melt to create a pond and spread that pond at the appropriate speed.
    2-3)Conscious to include welding rods if necessary
    2-4)It is also important to melt the pool by TIG welding from the hard-to-melt material. alt text

  3. Welding: The torch tip and the material should be separated by approximately 2-3 mm. In this time, I weld 2.3mmt steel plate to square pipe.
    alt text 3-1) Left image：1st try. Not smooth. It's hard to just weld a straight line.
    3-2) Right image: The most successful in this time.
    alt text NOTE:
    -Tungsten electrode contact with pool or welding rod is NG
    -The shape of the tip of the tungsten electrode is rounded at the tip or snagged, which makes welding difficult. If the tip of the tungsten electrode touches the welding material or is rolled into the pool during welding, the shape of the tungsten electrode tip will change, so the work should be stopped once and the electrode tip should be reshaped with a grinder or the like for the best welding.

  4. After flow:
    As prevention of oxidation of welds and electrodes, continuously injecting argon gas into the welding point until the argon gas stops injecting.

9. MIG vs TIG

  • Image after Welding (left:MIG, right:TIG) alt text
  • MIG: Automatic wire supply and high speed make welding work easy. On the other hand, there is a lot of spatter and the weld surface is more raised, so more grinder work is required than TIG.
  • TIG: Beautiful finish. Almost no spatter. On the other hand, welding speed is slow and is affected by wind.

10.Grinder

Finish the weld area with a grinder to create a smooth surface.

I use the Disc Grinder for finish.
alt text The disc I used alt text
I wear Protection, goggles and cow glove, safety shoes and work clothes (cotton 100%). alt text
I got advice that It is important to sharpen the disc grinder while pulling and to hold the grinder down with your hand from above. By doing so, it became possible to scrape off smoothly.
alt text
Rough Grinder:(Disc: Offset grinding wheel).
alt text
Finish Grinder: (Disc: Yanase Spark Disc A#40, A#60). The welds are not good (areas marked in green) were found after finishing. Forging during welding is important.　　 alt text

NOTE:
1. Do not leave flammable materials around the grinder.
2. Do not leave grinder while working.
3. Fix the material to be grind.
4. Install the disc with the plug unplugged from the outlet.
5. When the motor has rotated sufficiently, the grinding wheel is lightly placed on the material to be ground.
6. After the work, spatter and iron powder will be on my clothes and body. To prevent the risk of iron powder getting on the computer and causing a short circuit, I took the following measures: washing work clothes and taking a shower as soon as I got home.

Useful links: https://electrictoolboy.com/media/14837/ https://act-kougu.com/column/how-to-use_disk-grinder/

11. Assembly

Assembly by Welding alt text

alt text Trouble! 1cm gap! alt text It is assumed that the misalignment occurred because the surface of the square pipe was tilted outward due to the slanting surface caused by the grinder operation.　　 alt text Cut off the point welding we just made. alt text Check the angle of the inside as well as the outside, and re-point it. alt text Welding and grinder again. alt text
With re-welding, No gap! alt text The other day, I weld the bottom plate. alt text Heat from welding is best delivered to the surface.
alt text Masuoka san's welding is complete too! We done good welding. alt text

12. Add Casters

Prepare casters, bolts, washers, nuts and tools. alt text alt text Mark1 alt text Mark2 alt text Drill holes alt text Drill failure... and recovery alt text Happening! Two drills I just bought were damaged. I learned Cheap tools are no good. alt text Done! alt text