Welding 101

Welding 101

Benjamin B.

What it is Welding● v. to join together (metal pieces or parts) by heating the surfaces to the

point of melting using a blow torch, electric arc, or other means, and uniting

them by pressing, hammering, ect.○ We do this by using a consumable aluminium wire

● We use a MIG welder not a TIG welder○ A MIG welder works by using a continuously feeding spool of welding wire that burns, melts

and fuses both the base and parent metals together.

● Students weld all of our robots every year○ All of our robots since 2010 have been welded by our students, it’s a long

standing tradition on 2485 that we plan to continue.

Safety and Welding

● Safety is always the #1 priority ○ Before we can let you use the welder we want to make sure that you can do so safely

● Have the proper attire○ Wear long sleeved shirt and pants, as well as a welding jacket ○ Closed toed shoes○ Welding mask and gloves

● Aluminium conducts heat well○ Be smart about when it’s safe to touch your part after you’ve welded it, always give it time

to cool down

● Be sure that the piece is not grounded through you

Basic Set-Up

● Setting up the welder:○ Plug in the welder and adjust

settings○ Attach the gas nozzle

○ Attach ground (the clamp) to

the metal welding sheet (the

conductor)

○ Grind down metal welding

platform to give yourself a

clean workspace

Setting up the Welder

● Most important part of welding○ The beading of aluminium is very similar to sewing up a seam, the beading has to connect

both pieces of aluminium ○ If your bead is messy the piece will fall apart

● The best way to do it is in a repetitive shape ○ Circular shapes ○ Zig-Zags, a “weave bead”○ Find what works with you the best!

“The Bead”

“The Bead” examples

“The Bead” examples

Welder Settings● The settings you should weld at will both depend on the material you are

welding and your welder○ On 2485 we weld Aluminium and use a MIG welder

● There are two different settings to worry about ○ Volts running through the arc (power)○ Speed of the wire

● Pre-Season○ Practice, practice, practice! ○ Learn how to both weld as well as hold pieces for the person welding ○ The more time you put in, the better you’re going to be

● During the season○ The first three weeks of build welding is happening 24/7 ○ Having someone there to hold as well as weld is necessary at all times

● The more time you put in, the more you’re going to get out of it!○ That’s how most of FIRST robotics works, and life too

Time Commitment

Get excited for a great season!