15. Wildcard week

This week we went to the Ashot’s factory, where we used a plasma cutter and learned how to weld.

From the beginning, our technical support taught me how to use the welding machine.

This type of welding is called Metal Inert Gas (MIG) welding. The filler metal is added during the process to join the metals together. A shielding gas protects the molten pool of weld metal from reacting with elements in the atmosphere.

Components of a MIG Welding Gun:

• Control switch: Used to activate the welding process.
• Power cable: Transmits electrical energy to the electrode.
• Contact tip: Made of copper, reduces spatter during welding.
• Gas nozzle: Directs shielding gas.
• Gas hose: Carries shielding gas.
• Electrode conduit and power: Connects the electrode to the power source.
• Shielding gas flow: Ensures proper shielding.

We connect it to the table and it also becomes GND.

From the beginning, I learned to weld on a flat, ordinary surface. To know the technique.

These are my first attempts.

And here you can already see my progress, after which I switched to learning angle welding.

These yellow magnets In photo bellow ensure the staticity of the objects to be welded.

for corner welding, it is necessary to weld 2 end sections from the beginning.

Then we add the welding of the remaining part.

Then I also added a third piece of iron and welded the 3 together.

Individual Assignment

My individual work this week is to get something useful, functional from the waste.

That’s why I collected similar waste in different sizes. Having the right amount of iron and cast iron parts, I looked up references on the internet to see what I was going to make from them.

The final decision was to make a basket, in which it will be possible to place household items: bottles, such large objects, etc.

That’s why I found a disk, the size of which I will make my basket. And I started arranging my details around that.

Welding the basket

I started welding one by one.

Cast iron waste was more difficult to weld.

Cast iron is challenging to weld due to its unique properties:

• High Carbon Content: Cast iron contains a high percentage of carbon, making it brittle and prone to cracking during welding.
• Graphite Formation: During cooling, cast iron forms graphite flakes. These flakes act as stress concentrators, leading to cracks.
• Thermal Expansion Mismatch: Cast iron has low thermal expansion, causing stress when welded to materials with higher expansion rates.
• Preheating and Slow Cooling: To minimize cracking, preheat the cast iron and cool it slowly after welding

And also one of the cast iron parts bent after welding.

So for welding other parts I saw this example and thought about welding like this. It makes welding easier.

After welding the first side, I started welding the other axle. Then I connected the rest together.

Here is how easy it’s welding.

Inside of the basket. Welded the rounded parts.

After all the welds were done, I measured the inside diameters of the large rounds and designed the various parts in a 3D program to be cut with the plasma cutter.

All the rounds where I can weld my parts.

Designing Details

I learned to use and cut myself with a plasma cutter as well.

At first I designed a part in Solidworks and after moved it to Fusion360, so that I can generate the G-Code at once.

3D model of designed part.

I chose the type of tool (Plasma cutter).

type of the plasma cutter

And edited the nozzle parameters.

These parameters below are for small holes, so that it does not melt after cutting and does not change the appearance too much.

And these ones are for outline.

Then I chose the cutting direction. I made them all in one direction.

And here is the G-code. There are 2 G-codes separate for small holes and outline and with this Speed parameter bellow you can differ them.

Plasmacutting

Plasma cutting works by heating a stream of gas, typically air, to a high temperature until it becomes ionized and forms a plasma arc. The plasma arc is then directed through a constricted opening, or nozzle, where the pressure and temperature are increased, resulting in a high-speed stream of plasma that can cut through metal. The plasma arc is guided by a plasma torch, which is moved over the surface of the material being cut.

Plasma cutting is particularly effective for cutting metals such as steel, stainless steel, aluminum, and copper. The process is often used in metal fabrication and manufacturing.

Sheet of the cut parts.

This is what I’ve got after.

Here’s the interface of plasma cutter.

The process of cutting the machine.

The process

After cutting, the cut parts should be processed.

Cleaning redundant, unnecessary parts.

After cleaning and processing, I began to triangulate those parts

Welded parts from inside.

Welded parts from outside.

Final basket. Only legs are left.

Finaling

Then, finding waste valves, I used them as legs, a support for the basket.

For making welding easier I found some pedestals.

Here are welded legs from the bottom.

Zoom In.

And here it is!

Final shot!

Conclusion

This week was one of the most interesting weeks for me, and as much as I loved to do soldering, I also loved welding. Making something from wastes is even more enjoyable, because you feel the benefit of what you have done.