The following information is aimed at lighting fixtures that often break, have manufacturing defects. These are the smallest "wise things" that help welders to do their work efficiently. Therefore, it is not surprising if there is nothing said about magnetic angles or even prisms. These devices are often bought in the store.
Almost always in the process of welding there is a need for installation and fixing devices.
Welding devices can be of two types:
Since welding methods are progressing very quickly, the devices described may seem a little rare. But on the other hand, this means that it does not give way to more progressive and safer ways of connecting pipes in different conditions.
How to make clamps?
The clamp is the fixing device when welding various products.
Clamp - fastening device. It can not be uniquely attributed only to welding accessories, because it is used:
For different purposes, different strengths of this product are needed. Strong clamps are necessary for welding pipes and other metal things. Those that can be bought in the store very often do not withstand heavy loads, break at the most inopportune moment. Therefore it is worth trying to consider the devices made by hand.
It is easy to make such a device with your own hands, for this you need:
- steel sheet 10 mm thick;
- three nuts;
- several washers of large diameter;
- threaded pipe outside the size of the nuts.
For direct production it is necessary:
Clamp diagram: 1 - body; 2 - round timber; 3 - steel washer; 4 - clamping screw of steel rod.
- Cut a strip of steel sheet 50 cm long and 4 cm wide.
- Cut two strips and some extra small details:
- for static holding below 25 cm;
- mobile level of 10 cm;
- two rectangles 5 cm each, for fixing the movable part (s);
- small part (d) that will support the static part of the clamp.
In welding, such a device allows you to keep the construction of pipes in a fixed position. You can not worry that from the very first pulse of welding, the pipes will fall apart and the work will have to start anew.Back to table of contents
Comfortable welding at an angle of 90 °
Welding magnets can hold the product to be welded at a 90 ° angle.
In order for pipe welding not to be too troublesome and without an assistant, we came up with welding magnets that hold the pipes at an angle of 90 °. Earlier devices for this kind of work were made without the use of magnets.
This will require the following materials:
- metal square with a side of 20-25 cm;
- piece of square pipe;
- 3 small bolts and nuts to them;
- bolt thick with a diameter of 4 cm and a nut on 35;
- drill drill;
- a small metal cylinder with a ballpoint pen diameter;
- the holder for the cylinder, actually its handle;
- welding machine.
The pipes are 20 and 15 cm long welded to the square, on interchangeable sides, at the very corners, so that the ends of the pipes are on opposite sides of the square.
Make two auxiliary parts. To weld a U-shaped figure from the same pipes, approximately 10 cm long. The second one, using the same pipes, weld in the form of an equipolar trapezium with bases of 11.5 cm and 5.4 cm.
Calculations need to be made more precisely, the angle formed when crossing the side parts should be 90 °, so the lengths of the bases will accurately depend on the width of the pipes.
Installation scheme of welding magnets.
On the sides of the square at the corner, where the pipes are not welded, make an isosceles triangular cut. Weld a U-shape to it, pre-drilled a hole for a small bolt in the center of the upper rectangle. A bolt 4 cm wide with a nut should be placed in the gap between the square and the figure.
To attach a handle to the bolt, you can use a nut with a hole in which a thin rod moves freely.
In a small cylinder with a length of a smaller trapezoid base, thread the small bolts taken. The thread must be made along the tip of the large bolt, placing it in the center.
This workpiece fixture is almost done, it remains to drill a hole 5 cm above the center of the square, moving diagonally to the uncircumcised and its only free angle.
At the intersection of the trapezoid diagonals, make a hole in both such details. A cylindrical part will be inserted between them, in which the threads were previously threaded and a hole is drilled in the center. For further assembly of the fixture, it is necessary to prepare a nut for 35 for a bolt 4 cm wide. To do this, on one side, perform a through-thread without touching the opposite edges.
Clamps with permanent magnets: a - for assembling an angle joint, b - for assembling joints with various combinations of details; 1 — angular magnet, 2 — clamp, 3, 5 — magnetic elements, 4 — lever.
All further assembly is the correct sequence of joining parts. On the bolt with the handle already attached, put on the nut with the thread, while scrolling almost to the base. Attach a cylindrical part to the end of the bolt, bore a hole to the internal thread, and make a small bolt. Next, we fix the trapezoid figure with the help of bolts, one of which is embedded in the thread of the cylindrical part, the second one fixes the configuration from above, through the thread of the same cylindrical figure. The bolt with the prepared detail in its top is pulled under the U-shaped support, adjusting the threaded nut under it. Secure the bolt with a bolt that passes through the center of the U-shaped figure and is screwed into the thread of the special nut. The device, in fact, is ready for use. By rotating the bolt handle, you can relax it. By inserting the pipes at a right angle, fixing the fixture, you can weld.
Devices of this kind successfully replace welded magnets, which may be too expensive for simple household use.Back to table of contents
Welding with a non-consumable twist electrode
As you know, pipe welding is not the only type of welding, it is often performed to connect metal wires at joints, to twist and to repair or manufacture homemade thermocouples. To make this device, you may need an understanding of what welding is and how exactly the law of electromagnetic induction works.
Non-consumable electrode welding scheme.
Therefore, the device for welding is often going to do it yourself. There is a small “but”, wishing to make such a device, it should be borne in mind that the cost of the finished product is lower than the total amount for the purchase of all components. But if old transformers, switches from other devices, for example, already useless pliers, are used to create the device, then it is really worth trying to make devices for soldering or joining.
The method of connection used refers to the types of welding with a non-consumable electrode. As an electrode, you can use graphite, which is easily removed from a simple pencil, liquid flux is sold in electronics stores. Homemade flux can be made from a mixture of boric acid and water, brought to a state of gruel.
For the manufacture of devices you will need a transformer of 20-50 V, one connecting wire to connect to the network, two to connect, one to supply the electrode. As an electrode holder, you can use any available tools, it depends on the capabilities and availability of items in the arsenal, for example, a pharmacy syringe, a school tripod, cylinders or bolts.
In the process of making welding with a non-consumable electrode, twists will need a transformer coil.
The transformer coil for 20-20 V can be easily bought in the store, as well as the frame for the welding machine. But knowing the device of the transformer coil, having an extra, already unusable transformer, it can always be corrected by adding the necessary number of turns. Using the standard scheme of the welding machine, connect all the wires according to the instructions. If the device will be used by an electrician for welding twists, it is recommended to use working wires with a length of at least 3 m in order to have freedom of access to work on the ceiling.
It is worth mentioning the observance of security measures. There are some ways to protect the face, especially the eyes from welding. Of course, such a method of manufacturing a welding mask is very primitive, and in no case can it be used during welding of pipes, but only for thin wires. Take a dark plastic bottle from any drink, cut out glasses with very long arms and connect them at the back of the nape with a clamp or clip. For a short chance of work fit. But nevertheless, it is worth recalling that the eyes are being protected not only from the bright glow, but also from accidental contact with hot metal pieces. Therefore, replacing the mask with cartons and newspapers, a person is at great risk.Back to table of contents
Homemade electrode holders
General view of a simple electrode holder from a tube d¾ ": 1- electrode; 2 - spring; 3 - pipe; 4 - rubber hose; 5 - screw and nut M8; 6 - cable.
Self-made devices of this type have the greatest variety. This is due to the fact that, for example, too short wires go to the inverter welding machine. The types of holders mainly depend on what types of work will be performed. They will significantly differ depending on whether thick and durable pipes are being welded or soldering wires when joining or twisting.
So, for example, a steel rod and three pieces of wire about 10 cm long and 8 mm thick are taken. Two pieces of wire bend only slightly to the side, as for the plug, given that these parts will have different sides: left and right. In the middle there will be a third part of the wire, curved upwards from the side of contact with the metal rod, approximately to half of its length. First, the side parts are seized by welding, then the missing part is applied in the center, everything is well welded. Such excessive precaution is necessary in case of welding thick pipes, the additional winding of the wire will protect it from overheating. Eventually:
- the two parts of the wire, being on the rod, have the same length;
- the third leaves a small gap;
- pre-prepared insulated wire, stripped from both sides and wrapped with a thin wire at the edges;
- cut out a thick, rubbery piece of material that will be the handle of the holder;
- it is welded to the middle part of the wire;
- immediately after welding, while the fixture is hot, apply a gasket;
- The second end of the wire, wrapped and stripped, is clamped with a natural holder of the welding machine.
The device is ready to use, now the welder can move a much longer distance to perform the work.Back to table of contents
Some important secrets
In order to make a more solid holder for welding pipes, it is enough to go to the school workshop. There are many devices there, for example, a device for threading or various devices for drilling. It is very important to draw correctly the scheme by which the holder will be executed.
And another very important point: if a welding machine appeared in the house, it would not hurt to make a special rack for it. This is a place where you can store all the little things that require welding pipes.