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The TAB Guide to DIY Welding

The TAB Guide to DIY Welding

by Jackson Morley
Publisher: McGraw-Hill Education TAB
Release Date: May 2013
ISBN: 9780071799683
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Book Description

GET STARTED WITH METAL INERT GAS (MIG) WELDING!

A practical guide with step-by-step instructions and hands-on projects for newcomers to metalwork and MIG welding

The TAB Guide to DIY Welding shows you how to get started with MIG welding and metalworking. Inside, you'll find illustrated step-by-step instructions for making useful objects for around the home, as well as fun artistic projects. This easy-to-follow book takes you through setting up a metalworking studio, finding local resources for materials, and the safe operation of metal studio tools.

Everything you need to know about MIG welding is here in one handy resource.

You'll learn what steel is made of and the principles behind electrical welding. Then you'll learn how to acquire new steel, how to interface with steel suppliers, and how to find your own salvaged steel. After the basic principles of metalworking, hand and power tools are covered--and they're put to use through hands-on projects that allow you to develop new welding skills and establish building blocks for future tasks. By the end of the book, you’ll be able to create successful metal projects on your own, like a pro!

  • Illustrated instructions with photos and drawings provide step-by-step procedures and clear explanations
  • Projects include useful items for around your home and garden, including a log holder, plant stands and tables, a rolling garden cart, and a barbeque grill
  • Easy-to-follow examples and explanations for beginning artists, DIYers, and hobbyists
  • Expert advice from an experienced teacher of MIG welding courses
  • Course supplement for classroom and shop instruction
  • A list of online and local resources to help beginning metalworkers access a metalworking community

Table of Contents

  1. Cover
  2. About the Author
  3. Title Page
  4. Copyright Page
  5. Contents
  6. Preface
  7. Acknowledgments
  8. Part 1 Metalworking 101
    1. 1 Safety First
      1. General Shop Safety
      2. Shop Hazards
        1. Sharp Stuff
        2. Dirty Stuff
        3. Heat and Fire
        4. Intense Ultraviolet Radiation and Light
        5. Electricity
        6. Chemicals
        7. Gases
      3. Personal Protective Equipment (PPE)
        1. Clear Safety Glasses and Face Shields
        2. Welding Helmet
        3. Shaded Glasses and Face Shields (Shade Nos. 4–12)
        4. Gloves
        5. Arm, Neck, and Head Protection
        6. Boots
        7. Long Pants
        8. Hearing Protection
        9. Dust Masks
      4. Shop Safety Equipment
        1. Welding Screens
        2. Fire Extinguishers
        3. Covered Trash Cans
        4. First Aid Kit and Eyewash
        5. Ventilation
      5. Minimum Safety Equipment Review
        1. MIG Welder
        2. Plasma Cutter and Oxygen-Acetylene Torch
        3. Angle Grinder, Chop Saw, Bench Grinder, and Drill Press
        4. Roller and Hand Tools
        5. General Shop Safety
    2. 2 Welding 101
      1. What Is Welding?
      2. What Isn’t Welding?
        1. Welding
        2. Mechanical Connections
        3. Adhesives
        4. Soldering or Brazing
      3. How Welding Works
      4. Types of Welders
        1. Torch Welding
        2. Metal–Inert Gas (MIG) Welding or Gas-Metal Arc Welding (GMAW)
        3. Tungsten–Inert Gas (TIG) Welding or Gas-Tungsten Arc Welding (GTAW)
        4. Stick Welding (Shielded Metal Arc Welding)
      5. Types of Welds and Joints
      6. A Brief History of Welding
    3. 3 Steel
      1. What Is Steel?
        1. Plain-Carbon Steels
        2. Alloys
      2. Mild-Steel Properties
        1. Strength
        2. Conductivity
        3. Expansion and Contraction
        4. Corrosion and Rust
        5. Mill Scale
        6. Finishing
      3. How to Obtain Steel
        1. Buying Steel
        2. Finding Steel
    4. 4 Metalworking Studio
      1. Layout
        1. Safety Concerns
        2. Lighting
        3. Welding Table
        4. Cutting Table
        5. Cutting/Grinding Area
        6. Steel Storage
        7. Paint Area
      2. Buying Tools
      3. Cleaning and Maintenance
    5. 5 Basic Hand Tools
      1. Clamps
      2. Vice-Grips
      3. Measuring Tape
      4. Wire Cutters
      5. Magnetic Angles
      6. Other Layout Tools
      7. Slag Hammer
      8. Files
      9. Scribe
      10. Soapstone
    6. 6 Grinding and Cutting
      1. Angle Grinder
        1. Parts
        2. Types of Disks
        3. A Place to Grind
        4. Angle Grinder Safety
        5. Practice
      2. Bench Grinder
        1. Parts
        2. Safety
        3. Practice
      3. Chop Saw
      4. Parts
      5. Types of Disks
      6. Safety
      7. Practice
    7. 7 Drill Press
      1. Parts
      2. Accessories
        1. Center Punch
        2. Deburring Tool
        3. Adjustable Vice
        4. Automatic Center Finder
      3. Drill Bits
        1. Twist Bits
        2. Center Drill Bits
        3. Unibit
      4. Speeds
        1. Safety
      5. Drilling Practice
    8. 8 Roll Bending
      1. Parts
        1. Operation
        2. Safety
      2. Rolling Practice
    9. 9 Oxygen-Acetylene Torch
      1. Parts and Accessories
        1. Torch and Tank Setup
        2. Parts Detail
        3. Torch Detail
        4. Safety
      2. Torch Cutting
        1. Operation
        2. Cutting Practice
      3. Torch Welding
        1. Filler
        2. Flux
        3. Operation
        4. Welding Practice
      4. Torch Bending
        1. Operation
        2. Bending Practice
    10. 10 Plasma Cutter
      1. Parts
        1. Plasma Cutter
        2. Plasma Torch
        3. Accessories
        4. Safety
      2. Operation
        1. Amperage
        2. Travel Rate
        3. Angle of Torch
        4. Standoff
        5. Preparing to Cut
        6. Making a Cut
        7. Shutting Down the Plasma Cutter
      3. Practice
    11. 11 Metal–Inert Gas (MIG) Welder
      1. Parts
        1. Power Source and Transformer
        2. On/Off Switch
        3. Voltage and Wire-Feed Settings
        4. Negative, or Grounding, Clamp
        5. Welding Lead and Gun
        6. Shielding Gas and Regulator
        7. Weld Chart
      2. MIG Gun
        1. Gun
        2. Trigger
        3. Gas Nozzle
        4. Gas Diffuser
        5. Contact Tip
        6. Electrode/Filler
        7. Gas Line
      3. Inside a MIG Welder
        1. Spool of Welding Wire
        2. Feed Rollers
        3. Electrical Connections
      4. MIG Welder Consumables
        1. Shielding Gas
        2. Filler Wire and Contact Tip
      5. MIG Welder Adjustments
        1. Wire Speed/Feed
        2. Voltage
      6. You Are in Control
        1. Distance from Weld Area (Stick-Out)
        2. Speed
        3. Angle
        4. Pattern of Motion or Weave
        5. Steadiness
      7. Weld Vision
      8. Weld Orientation
        1. Flat
        2. Horizontal
        3. Vertical
        4. Overhead
        5. Safety
      9. Operation
        1. Setting Up Your Work Area and Welder
        2. Get Comfortable
      10. Practice
        1. Flat-Position Bead Making
        2. Flat-Position Weaving
        3. Flat-Position Tee Joint
        4. Making a Tee Corner
        5. Breaking a Weld
        6. Cutting Your Weld
        7. Visual Inspection
    12. 12 Finishing
      1. Steel Preparation
      2. Muriatic Acid
        1. Application
      3. Paint
        1. Brush Paint
        2. Spray Paint
      4. Clear Finish
      5. Wax
        1. Application
      6. Powder Coating
  9. Part 2 Projects
    1. 13 Project Preparation
      1. Materials
      2. Studio Access
      3. Time
    2. 14 Start from Scratch
    3. 15 Cube
    4. 16 Plant Stand
    5. 17 Candelabras
    6. 18 End Table
    7. 19 Fireplace Log Holder
      1. Finishing
    8. 20 Garden Cart
      1. Finishing
    9. 21 Barbecue
      1. Finishing
  10. Resources
    1. Education and Studio Resources (Listed West to East)
    2. General Welding and Online Resources
  11. Index