21 Awesome Welding tips-tricks and Techniques to Apply Today for Smooth Welding [2021]



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Welding tips-tricks and techniquesImagine you can use a small tweak in the method and get instant improvement in welding.

Or even better, you can use these 21 tips from below that you can apply right away to work like a wiz.

These tricks and technique will not only make your welding smooth, but it will also save your time and make you one of the better welders in your field. And you can apply these Right NOW.

Table of Contents

1. Get rid of the unnecessary sound with good Ground Clamps:

You are familiar with the earth-shattering sound from the MIG guns.

Do you know you can decrease it massively with a small tweak?

Here is how:

Just use a good ground clamp.

A bad ground is the primary cause of terrible sound which we get from the MIG gun. Just change the ground, and noise will decrease a lot.

Special Tip: Try to go for the copper ones as they are good conductors.

2. Use long stickouts for welding thin sheet metal:

People often wonder what stickout to use. This is often overlooked.

The wrong one might make a mess.

Here is the deal:

A proper stick out makes your welding smooth. Use long stick outs for thin metal.  When you are using a high amp, go for the long ones.

Special Tip: When you are going for short range, try to go for the ones which are less than half an inch in size. Shorter ones work better in thick metals.

3. Keep the angle of your torch 5 to 25 degree for an excellent weld:

The angle of your torch plays a vital role.

Now:

Keep the angle of your torch correctly for a good weld. If you are joining two similarly thick items, place the angle at center.

Special Tip: If the thickness is different, point the torch in the thicker one’s side.

4. Weld uphill for thick sheet metal for smooth penetration:

It often causes a dilemma when attacking a thick sheet metal.

But the solution is very simple, and you can use this technique right now.

If any sheet is thicker than one-fourth of an inch, always use uphill welding technique. It helps to penetrate smoothly.

How?

Just start from the bottom and go up.

5. Use auto darkening helmet to get precision and weld like a pro:

The regular helmet is not enough.

You will have to open and close it to have a look if the tips and pointers are in the right place.

Auto-darkening helmet allows doing the welding with precision. Without it, you won’t be able to view where it is pointing to without removing the front.

So, use it for good welding experience. A small error might destroy the panel. It will save lots of time. Always go for the best budget welding helmate under 100 with auto darkening feature.

6. Use solid wires on thin materials for clean weld:

Solid wires are a must when working on thin metals.

Solid wires comprise of Argon and Carbon-di-oxide or straightforward carbon-di-oxide. This works like a charm on thin materials.

Always go for the best mig wire.

Special Tip: Make sure the area is dirt free, and you will get a clean weld. This is necessary for auto body works.

7. Use magnet or Spark test to find the metal you are working on and avoid unnecessary complication:

Sometimes, we face a bit of difficulty to understand the material we are working on.

The best part?

One or two simple test can narrow it down.

First, use a magnet. If it is magnetic, it will come down to steel iron, nickel, cast iron, etc.

If this fails, you can guess with the sparks it generates. Carbon steel will make a ton of sparks, and you will be able to guess how much carbon in there by the pattern.

But this requires experience. If it is a 300 series stainless, it will sparkless and will be red. Titanium will go banana. It will be whitish and will go several feet.

8. Find out which rod is suitable for welding and use it effectively:

Finding the correct rod for welding is necessary. The wrong rod might cause a disaster.

This varies from person to person and the material. But here are some basic ideas:

  • Carbon steel : e70s2, 3, 4 or 6, er70s2
  • Stainless Steel: use er308L
  • Aluminum: use 4043 or 4943 which
  • Steel to copper: Silicon bronze
  • Cast iron: Nickel rod
  • Carbon steel: ER 309

Special Tip: Try to find out the material to use it properly. Check Tip 6 if you are not sure what you are dealing with.

9. Use the on-off technique to weld clear anodized aluminum

Welding anodized aluminum can be a nightmare. This often leaves a mark.

You can use an on-off switch or get it on and off manually when welding. This helps to break the coat and leaves little to no marks.

10. Move freely for broader welding and try to be in a flat position:

Movement is significant during movement. If you can move freely, your welding will be smoother.

When you are going for a side by side in the broader area, make sure to move smoothly along with the welder.  Make sure the heat is good.

If you do not move freely, excessive heat will generate and will cause damage. Controlling the travel speed is the key for good weld fusion.

You must make sure you give it enough time to penetrate.

Special Tip: When you are starting to learn to weld, always try to weld in a flat position. It will help you to keep the momentum going. You will see the good molten metal flow, good bead and you will get good coverage.

11. Use proper angle and distance of the torch:

Why is this important?

The length of the torch plays a vital role.

A proper distance will give you better control. When you are working on thinner material, your reach can be higher. It will generate less heat and less penetration. But if you are working on thick materials, you should hold it closer. This will give more heat to work with.

But make sure you are not too close or too far. Always keep a constant distance to keep the flow smooth.

Special Tip: Use filler metal and base metal together for a good weld.

12. Avoid big guns as much as possible to control the puddle:

Big guns can be attractive if you are new to welding. But it is very hard to control.

If you are not experienced, you will find it very difficult to control the puddle. Always start with the small guns gain control. Later you might shift to big guns.

Special Tip: To get a more significant build-up, you can make the wire speed faster or opt-in for bigger wire size.

13. Use smaller wire for thicker material:

Thicker metal sometimes causes a lot of problems.

Using smaller wire works well for the thicker materials.

Special Tip: Generally .035 is suitable for thick materials than .045. This tip is convenient for general type welding.

14. Install wiper for clean and consistent welding and clean the equipment when striking the arc:

Ever felt the need for a wiper? Just install it.

A wiper will help you to clean the wire clean and feeding well. If the machine and welder are neat and clean, it will work for a longer time than usual and help to get a problem free weld. If the wire is not clean, it will cause a problem in the feed.

When you are striking the arc, first clean the material properly. Otherwise, your welding might be contaminated. Use anti spatter dips and sprays to keep the nozzle clean.

15. Always have extra tips in hand:

Sometimes the contact tips burn back when you are looking to start it.

It happens for a different reason, Like, it might not be clean, it might have been used very often, or even the welding position is not proper. It is a very common scenario.

So, always keep a few in hand so that you can replace those immediately.

16. Use safety equipment and be safe when you are welding:

We see lots of accidents when welding. Always be safe than sorry. The fumes, sparks might cause a problem in your lungs, eyes, skins. Use welding gloves for your hand. best welding lens for your eyes. Use proper helmets.

a.) Use respirator to protect your lungs:

Always try to work in a place with lots of air flow. It will help you to breathe well and be active. Use a respirator to be safer. The fumes which are generated from welding can cause long-term effects if not cared properly.

Look at the color of the cartridge to understand what it is protecting you against. Change the R filters after every shift. P filters last longer if you are working near oil mists.

b.) Use proper welding gear to protect your skin:

Sometimes people tend to wear half sleeves in summer or hot condition. But do not do that in any circumstances.

Always use full pants, jackets, and other instruments to be safe. Always cover the skin to avoid severe burn. Remember that, an accident may occur at any time.

c.) Protect your eyes with proper helmet and lens:

When you are working with welding, you might go on for a long time. You will see its toll after a few hours. You will feel a sudden burn in your eye or other problems.

You can avoid it by using good helmet and lenses. Use auto darkening helmet to prevent lifting the mask when welding. The new models are excellent and let you keep the helmet on while welding.

17. The right length of tungsten electrode makes the solder smoother:

While welding, you must be aware of the whole scenario.

If you do not know the right length, you will not see where you are welding.

Guesswork is harmful in this sector.

When you are TIG welding, having the right length of the tungsten electrode is very important. If it is not long, you won’t see it.

And at the same time, if it is too far from the surface, you might melt your rod.

So, make sure you are using the right one.

18. Choose the right size of the rod that matches the metal:

Your rods thickness should match the metal. If you are using a thicker rod, you might make a hole because of the excessive heat.

It is controllable while TIG welding. But you need to have the perfect settings and tools for that. Use the best tungsten for tig welding for better performance.

19. Always clean the metal before welding:

Cleaning the metal will give you lots of facilities.

This is a must for smooth welding.

You might get away with MIG welding if you do not clean the metal. But TIG is different. You must clean it properly.

You just cannot cut the line on preparation. Otherwise, the end product can be messy.

Special Tip: Always use anti spatter dips and sprays to keep the nozzle clean. Usually, you get weld spatter on the tip. If it is not clean, it might get hot, and you will not get the right feed.

20. Always point your wire at the leading edge of the puddle for better accuracy:

Getting things right is very important while welding.

You have to be accurate no matter what.

If you point your wire at the leading edge of the puddle, you will get better accuracy.

Special Tip: Keep the wire in a smaller diameter if the position is not pleasant. It will minimize the drip.

21. Have a spotter to avoid the risk of fire:

When you are working with heavy machinery, there is always a chance that things might go wrong.

When you are working minutely, you tend to lose track of surrounding. It is always good to have someone around you, especially in a flammable area.

Special Tip: when you are working, always know what is beside you and where the exits are.

So, there is the complete list of 21 welding tips, tricks, and techniques you can apply now. Let us know which one of the tip you like most.

Frequently Asked Questions:

What is solar flux welding?

Ans: It is a complex chemical compound in the form of very fine powder. This is mixed with alcohol and brushed on the weld joint. This flux is formulated to shield the back of the weld joint from oxygen, dissipate heat and unwanted oxides, and dissipate heat.

It helps to clean the surface of the metal.

Are Hobart Welders Made in the USA?

Ans: Hobart welder 500559 Handler 140 is 25–140 amps designed to be operated on 115-volt household current. It is an industrial cast aluminum drive system.

How does gas tungsten arc welding work?

Ans: Gas tungsten arc welding (GTAW) is the process of the electric arc. It produces an arc between the work to be welded and a non-consumable electrode. The weld is shielded from the atmosphere by a shielding gas. And it forms an envelope around the weld area. Again, TIG welding aluminum also requires a shielding gas.

How dangerous is welding?

Ans: Prolonged exposure to welding fume may cause lung damage. Not only this but also various types of cancer, including lung, larynx and urinary tract. . Health effects from certain fumes may include metal fume fever, kidney damage, stomach ulcers and nervous system damage.

What is SMAW used for?

Ans: SMAW welding is a process of manual arc welding. It remains one of the most commonly used welding techniques that used today. This welding can be used for both repair welding and production. And it can be used in all welding positions on all ferrous metals.