Working with a welding machine in large-scale production with industrial equipment implies specialists who can and can set it up. A semi-automatic welding machine can be used at home, working even with not very large amounts of materials. Setting up a welding machine is one of the components of success and the quality of your future work with it. Therefore, it is very important to know its main stages, rules and recommendations in order to achieve optimal results.
Figure 1. Scheme of welding inverter semiautomatic device.
Automatic welding semiautomatic: features and functions of the tool
It is considered more popular than automatic welding, due to the greater density of welding current. Unlike manual mechanized welding, when working with a semi-automatic machine, you get the electrode feed to the welding area, and the welder must also do other operations manually. The electrode is a special wire.
The main modes of welding semiautomatic.
The power source is the use of a constant reverse current (for this you need to apply a minus to the product). The main parts of the semiautomatic device are: wire feeder, power source and burner (see figure 1). That it is considered the main functional body of the instrument. Thanks to her work, protective gas, flux, welding wire is supplied to the welding area. The giving mechanisms happen several types:
- pushing or pushing or universal.
Production of various series of semi-automatic welding machines has been established, using which you can perform many works (for example, arc welding of aluminum, steel, other metals, car body repair, etc.).Back to table of contents
Types of semi-automatic
They are classified according to different characteristics: according to the nature of the movement, which type of protection of the weld, and which type of wire.
Diagram of the front panel of the inverter.
- On the basis of the nature of the movement, a semi-automatic stationary class is distinguished (it is used in large-scale or mass production), as well as portable and mobile equipment.
- According to the cost of protection of the weld, three types of tools are classified. The seam can be protected by protective gases, cored wire or be under a layer of flux.
- The welding semiautomatic device can have various types of a wire. It is considered universal if there is a connection with two wires - aluminum and steel. The other two subspecies of tools use either solid steel wire or solid aluminum wire.
Advantages and weaknesses of the semi-automatic
Like any other equipment, this tool has its strengths and weaknesses. The advantages and advantages include the following features of the welding machine:
The work of the welding machine.
- With it you can work with thin-sheet steel, welding parts and parts whose thickness is up to 0.5 mm;
- It has a low threshold of sensitivity to corrosion, rust and other contaminants or harmful processes for the base metal;
- An important role is also played by its adequate cost, which is much lower than other types of welding;
- With such a device you can work with metals that have an external coating. It also makes soldering of galvanized parts, without damaging the zinc coating.
The device burner semi-automatic.
But there are also disadvantages. The main thing is that the metal will spray if you do not use protective gas. The second significant disadvantage of the semiautomatic device is the large radiation of its open arc.
Despite this, this type of welding is very often used in various industries, as well as in car-care centers or for homework. Most often, semi-automatic machines are used if you need to cook black and stainless steel, aluminum. As a protective gas, mixtures of carbon dioxide, helium, argon are widely used or taken in pure form.Back to table of contents
How to set up a semi-automatic welding machine
Before you start working, you need to configure the device.
To do this, you need to know the basic steps of setting up a semi-automatic device and a number of its parameters and characteristics in order to do everything correctly.
All the necessary data will be based on which semi-automatic machine you have chosen and purchased. After all, before this you have to decide on what the main conditions of its operation are assumed. Here are the approximate parameters that you should definitely consider:
Table current strength.
- how intensive will be the operation of the semiautomatic device (professional work or domestic use);
- what is the expected load capacity of the mains;
- what you want to weld (non-ferrous metal, stainless or low carbon steel, aluminum, etc.);
- what you put forward the requirements for the quality of welding (the degree of responsibility of the welded structures);
- what is the assumed thickness of the metals being welded;
- What character will have to have welded joints (according to the length of the welds, their spatial position, dimensions of structures, etc.).
Basic configuration steps
The influence of welding on the shape of the seam.
First, select the strength of the welding current, taking into account the thickness of the metal that you will cook. Be sure to thoroughly study the manual or instruction manual for the semi-automatic machine, because they include tables in which you will find the correspondences of these two values. Consider that with a low welding current the device will cook badly. In some models, you can find voltage indicators instead of current indicators. There are no special differences between them, because you will make the choice of settings in the same way: expose the stronger the voltage, the more the thickness of the metal being welded is assumed.
Further, following the instructions of the table and (in any case, not by eye), adjust the desired wire feed speed. It can be adjusted using interchangeable gears, which are attached to the machine. There are models with special gearboxes.
Classification of semi-automatic.
Now you can proceed to setting the current and voltage. This is done using adjusting devices. Power sources can be different: a welding transformer or a DC machine. Be sure to check your settings on trial products (experienced surfacing), if necessary, adjusting the welding mode to the most optimal. The proof that everything worked out right for you is melted flux (in the required amount), normal formation of a roller, stable welded arc. Then you can try to work with the basic material.
As for the wire, its configuration is quite simple. Its supply through a special hose to or from the mouthpiece is regulated by the position of the switch (lever), which you can find on the hardware box. When you move the switch to the “Forward” position, you will ensure that the wire flows in the direction of the holder to the welding point. Accordingly, if the lever is set to “Back”, the wire will be fed to the coil side. Just select and configure the mode you want.
To get started, push the lever to the “Forward” position. When the funnel is filled with flux, install the holder so that the tip of the mouthpiece is located in the weld zone. Now, it will be necessary to open the valve of the flux funnel and press the “Start” button, while simultaneously making a slight movement (striking) with the holder at the welding point. As a result of your actions, the arc should ignite and the welding process itself should begin.Back to table of contents
Important nuances when setting up a semiautomatic device and working with it
Ten rules of welding.
The welding mode that you select depends on many factors and components. You must take them into account.
Remember that if you use gas in your work, before you start welding directly, you must open the valve on the cylinder and set the pressure you need on the gearbox. Be sure to make sure that the cylinder is intact and in good condition before starting work. Calculate the flow of shielding gas optimally, because it will form a protective environment in the arc zone. Remember to choose a gas that matches the type and thickness of the material you are working with. It is necessary to fix a cylinder in the most reliable way.
It is worth knowing that, according to the parameter of the electrode feed rate, the setting will depend on the specific indicator of the thickness of the metal with which you work, the composition and the diameter of the electrode itself. If the feed rate is set very fast, then the electrode may not have time to melt, so you will not get a seam. Then try to reduce the parameters a little, but do not overdo it. With a very low speed, you will get too fast combustion of the electrode, which will not have time to melt the metal. The seam can either fail, or it will be very poor quality. Only after many trials and mistakes with each concrete indicator of metal thickness you will develop for yourself your own table, relevant for your semi-automatic machine and the tasks that you set for it.
Do not overload the machine in order not to jeopardize your health or reduce its resources. Note that welding cannot take place continuously. Regulated breaks are obligatory. Remember about the necessary ventilation of the room in which the welding work is going on. This will help you reduce the amount of harmful aerosols released during welding.
Do not forget about the necessary maintenance of the equipment. This will increase the duration of his work. Weld especially in clothing that is designed for this purpose. A very important point is that everything should be dry on you so that there is no risk of electric shock. Special safety glasses with a light filter will help you to save your eyesight. Watch the filter markings: they must correspond to the current range that you use when welding.
Remember the elementary safety rules when working with a welding machine and be sure to follow them. Carefully read the instructions for use and the characteristics of the tool to be aware of all its features.