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HOME PAGE
Welding Advisers for any welding shop. Welding Plan to troubleshoot and solve welding problems. How to select a Process for a welding Project. How to plan for a Career in Welding. Understanding Welding Information. How Better Welding Plans provide better Quality.



Welding Consultation
Welding Consultation helps overcoming production hurdles and failures. Expose the secrets hidden by your fearful workforce. Find the real causes undermining acceptable results. Welding Consultation for Decision Makers: how to benefit from expert help.

Frequently Asked Questions
Practical Answers to frequent Questions. Weld Thickness problems, Repair techniques, Welding Dissimilar Materials, Unweldable Steels, Brazing, Hardening, Grinding and more...

Welding Articles
Welding Articles by this Author are condensed expositions likely to enlighten certain aspects of welding subjects useful for general understanding. They are also the starting point for more deep investigation of crucially important features.

Welding Talk
Welding Talk is the page open to the public. It will host readers contributions, feedback, comments, suggestions and whatever interests the community of people who share welding interests.

Welding Books
Welding Books and Welding Information. Find in Manuals and Handbooks the knowledge and experience that every serious person interested in welding should study and peruse.

Subscription
Your Subscription is taken in this page. We respect YOUR PRIVACY: We promise we will never sell or give away your e-mail address. We will use it ONLY to send you our opt-in most recent Practical Welding Letter and any information we may judge to be of some use to you. You will always have the possibility to unsubscribe to be deleted from our list.

Welding Topics
This Page lists the Titles of the most important Articles from previous issues of our Practical Welding Letter, the monthly publication you can get delivered at no cost in your E-mail Inbox, by filling the Subscription Form above. The links permit immediate reading and downloading.

Index of Past Issues of PWL
This page provides links to all the Practical Welding Letters issued in the past and permits to download those of interest.

Welding Resources
This page on Welding Resources provides links to rich pages supplying a wealth of online information on welding, metallurgy and associated subjects, organized by topics, and to be regularly updated.
Easy to scan and review.

The Welding Blog
The Blog of the Welding Advisers Site registers all new and updated pages of the Website as soon as they are published. It is therefore a useful tool for following the growth of the site and the appearance of informative pages. By monitoring closely the Blog one can keep abreast of new items.

• PROCESSES
  Welding history and development for essential savings. Four types of Underwater Welding. Fusion or Pressure welding. All other processes for different projects including High Energy Processes.

  • Friction Welding Processes
    Friction Welding Low Cost High Yield Welding Processes. Friction Welding for saving on Costly Metal. For Copper to Aluminum joints. Solid State Weld without Fusion. Salvaging expensive Rotors. Short Cycle, Mass Production. Advantages and Limitations.
  • Friction Stir Welding.
    Friction Stir Welding is an innovative solid state process successfully applied to industrial production in most different situations. It is characterized by high welding speed and quality, low heat input, minimum deformation and residual stresses and economic production.
  • Flash Welding Processes
    Flash Welding, High Quality Mass Butt Welding Process. Flash Welding, economical Process for reliable High Quality Butt Welds in many Materials. Qualifiable for demanding Aerospace Applications. Fully Feedback controllable Automatic Mass Production Process.
  • Resistance Welding Processes
    
  Resistance Welding Related Processes. Resistance Welding and its Applications. Requirements for Stainless Steel. Spot Welding for "unweldable" Aluminum Alloys. Coated Steel Sheets: are they spot weldable? Where is Projection Welding used? Shear Strength Specification Requirements.

  

  • Resistance Welding Tips
    Resistance Welding Tips may help in setting up welding schedules or for troubleshooting. Introduction to feedback control for consistent performance.
  • Projection Welding
    Projection Welding is a process suitable for sheet to sheet welding with embossed projections. It enables also economic application of annular bodies and nuts to plates, and cross wire resistance welding with remarkable advantages.
  • Upset Welding
    Upset Welding end-to-end bars or strips by resistance heat and pressure. Rapid high quality, repetitive joints with simple, reliable equipment. Suitable for difficult to weld materials.

  • Gas Welding Processes
    Gas Welding, Oxyacetylene welding: versatile, low cost, portable, self sufficient. Suited to short runs, repairs, field work. Best for thin thickness. Ideal for artistic, home and hobby work. Adaptable to cutting, brazing, hard-surfacing. Highly controllable, requires skill.

    • Oxyacetylene Welding Tips
      Tips for versatile and economic Oxyacetylene Welding process. Suitable for a large selection of jobs. Self contained, portable outfits, useful even in difficult situations, with proper skills.

  • Arc Welding Processes
    Welding-arc, a series of varied economic welding processes: used for short runs, but also for ships, bridges, structures. Manual process for intricate settings. Automated for long or repetitive joints. Adapted to different materials. Suitable for special jobs (underwater).

    • Shielded Metal Arc Welding Tips
      Tips for improving skill with Shielded Metal Arc Welding knowledge. How to select your power source. Current range and polarity, duty cycle, current density, low-hydrogen, AWS electrode classification.
    • Tig Welding Tips
      Tips on Tig Welding with process specific instructions. Advantages and Limitations. Fine points on polarity and usability. Special wave forms explained. How to develop Tig parameters.
    • Mig Welding Tips
      Mig Welding Tips and common misconceptions. Polarity, power supplies and self regulated arc length. Metal Transfer Modes. Slope and Inductance Control. Where else to find useful References.
    • Plasma Welding Tips
      Plasma Welding Tips: its unique characteristics are perfectly adapted to high quality welds both at fractional and at elevated currents. Different modes for demanding applications. Melt-in mode for delicate jobs and keyhole mode for full penetration. Advantages and Limitations.
    • Flux Cored Arc Welding Tips
      Tips on Flux Cored Arc Welding for cost effective high deposition rate applications. A more tolerant process requiring less welder's skill. Better quality, contamination tolerant, crack resistant, higher impact. With or without shielding gas.
    • Submerged Arc Welding Tips
      Submerged Arc Welding Tips are essential for selecting and planning one of the most productive processes. Many interactive parameters add complexity but also suggest solutions to overcome difficulties in qualifying procedures.

    • Vertical Welding Tips
      Vertical-welding-tips are essential to become skilled in more demanding welding positions. Training and guided exercise help develop the skills that make an apprentice an expert welder.
    • Stud Welding
      Stud Welding must be adopted at the design stage. Applied thoughtfully it provides reliable joints and economy of manufacturing. The correct solution for suitable applications.
    • Welding Underwater Processes
      Welding Underwater, Structure Building and Repair deep Under Water, Hyperbaric Enclosure Welding, Welding Underwater Specifications. Exceptional Conditions influence Quality and Properties. Nuclear Pool Repairs. Changes with Depth. Hydrogen Induced Cracking.

  • High Energy Welding Processes
    Electron Beam Welding, Laser Beam Welding, High Energy Welding, High Power Density Welding, Low Heat Input. Deep, narrow keyhole penetration, thin Heat Affected Zone. Joining dissimilar materials. Minimum contamination, distortion and shrinkage. Least influence on properties.

  • Additional Processes
    Additional-processes are specialized technologies related to welding, capable of performing unique operations unavailable with regular sets. Dedicated equipment and acquired skills must be made available for full exploitation of capabilities. Knowledge and experience help in selecting and applying correctly techniques and materials.

    • Micro Welding Processes
      Micro Welding Processes for miniature devices. Resistance, arc, laser micro welding equipment. Micro-welding for manufacturing of thin, tiny miniature devices. Micro-welding for repair of worn out costly molds and dies. For jewelry and hobby. For anything too fine to be welded by regular means.

    

    • Repair Welding
      Repair Welding can be used to repair some service failures, but needs knowledge and experience for correct application. Not for highly stressed items (gears, shafts) or for lifting equipment.

    • Pipe and Tube Welding
      Pipe and Tube Welding summary of knowledge, tips, requirements. Procedure development plan. Warning of lack of fusion. Important macro testing. Testing and Training. Report records and documentation.
    • Cold Welding
      Cold Welding, performed without melting, is a solid state process that brings in intimate contact by mechanical force, locally, the surfaces to be joined. This solid state welding has many advantages, permitting also dissimilar metals combinations to be lap- or butt-welded.
    • Brazing
      Brazing processes and joint requirements. Dissimilar material joining. Low heat, rapid application, many brazing-alloys, strong joints, suitable for one off and for mass production. Skill and perfect cleaning required, joints well designed, flux generally needed. No base metal fusion.
    • Brazing Joint Design
      Brazing Joint Design must apply good practice, issue of understanding the basic principles of the process. Rich Resources are available for serious learning.
    • Brazing Heating
      Brazing Heating comes in many forms, each one best adapted to specific conditions. The most economic brazing process should be sought that meets requirements.

    

    • Brazing Aluminum
      Brazing Aluminum is a complex technological challenge requiring deep understanding and thorough preparation. Know-how presented here and useful References provide the necessary background on which to build a successful practice.

    

    • Brazing Copper
      Brazing Copper has to be approached with a thorough study of copper metallurgy, heat influence and filler metal compatibility. Then the most economic process must be sought assuring required properties and functionality.

    

    • Brazing Stainless Steel
      Brazing Stainless Steel offers unique advantages in special situations as lower temperature is suitable to join dissimilar metals. Versatile processes for meeting exacting requirements.

    

    • Brazing Cast Iron
      Brazing Cast Iron has to address problems to improve cleanliness and wettability. A wide selection of available filler metals helps in finding the brazing temperature suited to process and service.

    

    • Brazing Titanium
      Brazing Titanium can be the preferred joining solution in selected cases. Due to high material and processing costs, the actual filler metal and process has to be studied and tested. Joint corrosion resistance to be validated.

    

    • Brazing Ceramic
      Brazing Ceramic is a complex subject which requires thorough understanding of basic properties of ceramics and of metals. Successful applications depend on development of suitable materials and procedures.

    

    • Brazing Steel
      Brazing Steel has many advantages in specific cases, providing ease and flexibility of manufacturing for tough joints. Basics must be mastered and some research must be done before launching production.

    

    • Brazing Nickel
      Brazing Nickel needs attention to preparation, filler selection, heating method and protective atmosphere. Provides high temperature strong joints not easily remelted. Used for electronics and engine applications.

    • Braze Welding
      Braze Welding joins many metals. For building up layers. Wide openings filling. Oxyacetylene low temperature process. No base metal melting. Faster process with less heat.
    • Soldering
      Soldering, low temperature joining for many uses, easy and effective. Manual applications for single items. Or automatic for economic mass production. No base metal fusion. Limited strength.
    • Torch and Arc Cutting
      Cutting Gas or Arc Torch and methods. Cutting materials by economic means. How to deal with difficult metals. Underwater by hydrogen-torch. A new gasoline burning cutting-torch. Cutting safety.

    

    • Abrasive Water Jet Cutting
      Abrasive Water Jet Cutting can be a very economic cutting process for the right applications. Exclusive solution for cutting containers of explosive materials. Suitable for almost any material from thin to thick.

    • Hardfacing
      Hardfacing with base metal melting for longer economic operation, for wear and abrasion resistance. Overlays provide abrasion- and corrosion-resistance where needed most. Salvaging costly items by adding new service life to rebuilt worn out implements.
    • Thermal Spray
      Thermal Spray, also known as metal spraying, ceramic spraying, flame spray, metallizing, plasma spray and plasma coating, improves performance, lengthens working life, reduces manufacturing costs, reclaims scrap parts. Provides unequalled design flexibility. No base metal fusion.
    • Adhesive Bonding
      Structural Adhesive Bonding for joining most different materials. Surface chemical bond irrespective of metallurgical properties. All important design, selection, preparation, application and curing. Alternative joining method. No base metal fusion.
    • Adhesive Joint Design
      Adhesive Joint Design is a complex discipline. Stresses developing upon load application must be understood. For expanding structural application in future more research and richer experience will be needed.
    • Mechanical Fastening
      Mechanical Fastening, performed with different means, permits the creation of joints without objectionable influence on the metallurgical structure of metals. It is a useful alternative when welding processes would cause unacceptable damage to the parts.
    • Case Hardening
      Case-hardening is accomplished by producing a high-carbon martensitic case with good wear and fatigue resistance upon a tough, low-carbon steel core. Different processes can be selected for accommodating the most suitable characteristics for different applications. Welding should not be attempted on Case hardened layers.

    • Surface Engineering
      Surface Engineering processes provide products with resistance to aggressive environment for long life. Selection of suitable finish conditions is necessary to deal with demanding specific service.

    • Diffusion Welding
      Diffusion Welding does without fusion, for tough and durable joints of unique requirements. Highest quality properties, that other processes cannot deliver.

  
  

• ECONOMICS
  Welding Economics is the key to a successful business. Process expertise is a must. Being able to perform uncommon processes on exotic materials is a real asset. Know how to adapt to a changing market.

  • Welding Cost Estimate
    Welding-cost estimate: the useful tools for solid business How to calculate real expenses. How to compare the cost of competing processes. How to improve the bottom line. How to save by planning.
  • Starting a Welding Shop Starting up a Welding Shop requirements: all you need to know. Business plan, target market research, mapping the road to success. Financing, performance analysis. Location, Customer base. Welding Equipment and adequate workforce. Safety issues.

• EQUIPMENT
  Welding Equipment for all processes. How to select. Welding Resistance and Friction Welding machines. Different Welding Arc machines, Electronbeam Welders, Laser welding machines. Robot and orbital welding equipment.

  • Friction Welding Equipment
    Friction Welding equipment for economic high productivity joining. Dissimilar material joining machines. Direct drive and Inertia drive Equipment. Used for automotive and aerospace applications. Special equipment for repair welding of worn out or damaged expensive items.
  • Resistance Welding Equipment
    Resistance Welding Equipment for economic high quality joining. Fast, efficient, low cost joining method. Unskilled workforce. Special equipment for difficult jobs. Automated equipment for automotive applications.
  • Gas Welding Equipment
    Gas Welding Equipment for home and hobby work. Most economic and versatile. Oxyacetylene outfit: a must for every shop. For general use low cost installation. Best for repair and short run, suitable also for brazing, hardfacing and cutting.
  • Arc Welding Equipment
    Arc Welding Equipment for manual or mechanized work. Suited for short runs in a small shop, even for home and hobby work. But also for welding ships, bridges, structures. Modern power supplies and accessories for welding all metals.
  • High Energy Welding Equipment
    Electronbeam-welders: High-tech joining with High Energy. Concentrated power for High penetration, Low Heat input. Best solutions for unique results.
  • Welding Positioner
    Welding-positioner types and features. What it is good for. The operator's job is simplified. Occupational risks reduced. More production in less time. Favorable Return on Investment.
  • Robotic Arc Welding
    Robotic-arc-welding is a possible answer to skilled workforce shortage. It needs integration, planning, testing by properly trained and qualified personnel. Potential gains are remarkable. Difficulties cannot be ignored.

• MATERIALS
  Welding Aluminum. Weldability of aluminum alloys. Which Aluminum properties influence Welding. Heat treated aluminum alloys and the consequences of welding. Fabricated aluminum.

  • Metals Knowledge
    Metals-Knowledge links to authoritative pages available through the Internet from Institutes, Academic and Commercial Sources. A valuable asset in addition to your professional Library to assist you in your Professional Growth.
  • Cast Iron Welding
    Welding Cast Iron of different types is easy to perform: see how. Weldability of cast iron. Suitable processes and filler metals. Arc and oxyacetylene welding.
  • Steel Welding
    Welding Steel and Iron Base alloys is presented in this page. A brief account on the importance and versatility of iron and steel in developing their most wanted properties can be found. Weldability of steels and iron base alloys. What makes a material easy or hard to weld. Brittle heat affected zone.
  • Alloy Steel Welding
    Welding of Alloy Steel while preventing cracking risks. Hardenable steels welding. The precautions: preheat and postheat. Weldability and Hardenability. Hydrogen Underbead Cracking. Carbon Equivalent.

  

  • Creep Resistant Steels
    Creep Resistant Steels are designed to perform satisfactorily for long time at high service temperatures. Their composition requires special precautions, notably preheating, for successful welding.
  • Tool Steel Welding
    Welding of Tool Steel, to repair or rebuild unusable tools. How to weld annealed or hardened tool steels. Preventing cracks and deformations by preheat and postheat.
  • Stainless Steel Welding
    Welding-stainless. Learn how to weld austenitic stainless steels by all processes. Sensitization dangers and remedies. Weldability of ferritic stainless steels. Processes and materials.
  • Aluminum Welding
    Welding Aluminum, welding non heat treatable aluminum alloys. Which heat treatable alloys can be welded and how. Weld influence on properties.
  • Magnesium Welding
    Welding Magnesium for construction or repair. Cast or fabricated parts with unique properties and advantages. Easy to work with, needs safety precautions.
  • Titanium Welding
    Welding Titanium. Easy to weld if you learn how, using vacuum or protective atmosphere. Which heat treatments are favorable to welds. Weld influence on properties.
  • Copper Welding
    Welding Copper and copper alloys: feasible but tricky. High energy copper welding in vacuum or protective atmosphere. How to weld which copper alloys. Weld influence on properties.
  • Heat Resisting Alloys Welding
    Welding Heat Resisting alloys. What can it do for you? Furnaces and hot parts, combustors and Gas Turbine components. Weld influence on properties.
  • Joining Lead Tin Zinc
    Joining Lead Tin Zinc is not difficult but needs attention to these metals. Resistance welding is applied to coated steels. Soldering is most common. Stud welding for zinc castings.

  

  • Joining Galvanized Steels
    Joining Galvanized Steels has a long history of successful applications. The special problems are quite understood and suitable solutions are currently applied. Fume extraction and personal masks should be used.

  • Refractory Metals
    Refractory Metals for corrosion resistance, high temperature service. Joining, welding and brazing. Applications, fabrication, oxidation. Ductile to brittle transition Temperature. Brittle Interstitials.
  • Precious Metals
    Precious Metals for exceptional properties. Expensive materials for economic solutions. Amazing applications with the most suitable materials.
  • Welding of Plastics
    Welding Plastics for corrosion resistant containers, scrubbers, piping systems for water, sewer, drainage, irrigation, natural gas, chemicals and pharmaceuticals.
  • Material Identification
    Material Identification is essential for any welding job. How to identify the material type. Simple tests, tips and suggestions. Quantitative Analysis: is it important? Not always.

• JOBS and CAREERS
  Welding Career and Jobs: How to plan for. How to choose a Welding School. How to build a Training Plan. How to select the most wanted Certifications. How to look for Welding Jobs.

  • Welding Education and Training
    Welding Education and Training: plan to achieve results, it is all in your hands. Program aggressively to implement incremental progress. Challenge yourself to master a multifarious profession. Better Education for a more successful career. Never rest on your laurels. Pursue Education at an ever higher level.
  • Welding Books
    Welding Books, Welding information, knowledge and experience in manuals and handbooks that every serious person interested in welding should study and peruse. Only learning with dedication and persistence is the way to progress.
  • Welding Design
    Welding Design is the essential foundation for welded structures to economic operation and long service life. Why good Welding Design requires dedicated efforts to learn from experience. Design team work preferred. Expert advice needed.
  • Welding Information
    Welding Information: how to present and how to spread. How to interpret a welding drawing. How to understand and meet welding requirements. How to follow specification requirements. How to accomplish a welding job.
  • Welding Procedures
    Welding Procedures: detailed and explained know how. How to realize a welding job. What to do and how to meet welding requirements. Why and how to follow welding procedures. How to meet specific requirements. How to accomplish a welding job.
  • Welding Properties
    Welding Properties: the lessons learnt the hard way. Spectacular failures and their investigations. The importance of ductility and what affects it. Temperature dependence of critical properties. Not only strength is required.
  • Welding Software
    Welding Software, a necessary toolkit for streamlining performance, for easy Document writing and managing, for record keeping of Welding workforce information, for weld operations management.

  • Examination Questions
    Examination Questions to be listed in this page will reflect the current practice in official Welding Examinations as proposed by readers learning towards Certification tests. Answers proposed by readers will be checked to be correct before publication.

• QUALITY
  Welding Codes and their application. Welding Specifications/Standards and their significance. Welding Test as a base for quality. The Quality Manual establishes duties and responsibilities in any manufacturing operation. WPS and record keeping.

  • Welding Standards
    Welding Standards are practical tools. Recommendations and Requirements for Quality Welding. Specifications for Materials and Consumables. Qualified Welding Procedures. Safety Instructions. Nondestructive Inspectors Certification.
  • Welding Control
    Welding Control in automatic equipment. Microprocessors for electronic control of crucial parameters. Feedback control and robotic operation. Statistical process control in welding operations.
  • Welding Testing
    Welding Testing: proof of performance and educative tool. Improving reliability through monitoring of periodic check. Simple destructive test for immediate quality assessment. Trial and error.
  • Welding Qualification
    Welding Qualification of Personnel and Procedures assure suitability for service of Welded Constructions. Responsibility, Witnessing, Examination, Testing, Qualification and Certification to meet Code requirements.
  • Welding Inspection
    Welding Inspection methods for quality and economy. Service conditions and inspection severity. Evaluation of discontinuities: accept, repair or reject.

  

  • Brazing Inspection
    Brazing-inspection is the complex of rules and methods applied to determine if all precautions and operations were correctly performed and if the requirements are met in the brazed joints.
  • Weld Macro
    Weld Macro of a test piece: a powerful tool. Weld section quality in full view. How to see a weld inside. Easy preparation procedure. Importance and need for visual Weld Macro Examination.
  • Welding Distortion
    Welding Distortion: understand cause and effect. How to use residual stresses to straighten welded joints. What to do and how to control warping. How to decrease residual welding stresses. Which procedures reduce deformation. How to meet dimensional requirements.
  • Welding Defects
    Welding Defects: definition and how to look for them. Between discontinuities and defects. Acceptance limits for harmless discontinuities. Visual and internal defects. Defect most common types.
  • Welding Failures
    Failures investigation: many possible origins. Sorting out causes and effects. Run out conditions or inadequate manufacturing? Start with correct and complete description of evidence. Knowledge and experience are most important ingredients.
  • Weld Cracking
    Cracking is a major concern in designing welded structures. Knowledge of cracks sources helps in avoiding dangerous outcome. How to tell the difference among crack types.
  • Welding Liability
    Liability of welded products: dangers and precautions. What to prepare against lawsuits. How to build a defense line. How to avoid claims for damage.

• SAFETY
  Welding-helmet and welding protective gear. Look for Safety Information links. Welding precautions and safe practices. Welding education and work discipline. Explaining the dangers and their significance. Implementing welding safety rules to achieve peace of mind in a welding enterprise.

  • Hobby and Home Welding
    Hobby Welding for the weekend welder. Simple equipment for diversified cabability. Safety first: learning and training. Materials and accessories to get best results.
  • Welding Projects
    Welding Projects as self selected tasks to exploit one's welding skills and realize with joy useful or decorative items. Lists and links of proposed welding projects are given in this page with a few warnings.
  • Welding Art Books and Video
    Introduction to welded metal Artbooks. How-to weld artwork and jewelry for creative Hobby welders. Artbooks: perfect gifts for welders and welding students.

  • Welding Art
    Welding Art presents Artworks photos and comments contributed by Artists who use welding as their tool of expression. An Invitation Form is included so that interested Readers can easily send new Contributions.

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Provocative reading for curious visitors who may whish to dig deeper into the matter and to consider to give it a try...

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  Building a Site on Welding: the story of a challenge. Planning for Retirement. Enlightenment for free. Study and preparation. Trial and error. Importance of persistence. Which best tools were used.
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