Welding Tools
The common welding tools used for gas welding purposes are as follows:
1. Spanner
2. Hammer
3. Pliers
4. Chisel
5. Tongs
6. Cylinder key
7. Wire brush
8. Clamps
9. Angular grinder
10. Spark lighter
11. Try square
12. Tip cleaner
13. Files
14. Centre punch
15. Scale and weld-gauge
16. Steel tape
#1 Spanner
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Spanners are generally used for tightening or loosening various fasteners.
These are designed with drop-forge steel or carbon steel. But in welding, a
double-ended spanner is used for tightening and opening the nuts of the
welding apparatus and job.
#2 Hammer
Welding hammers are essential tools used for chipping to remove slab-coating
from the weld area. It is used for shaping the job. Normally a 500 grams
hammer is used for the purpose. There are three types of hammers – ball
pane, cross pane, and straight one. For large-sized jobs, a Sledgehammer
may be used.
#3 Pliers
Welding pliers are specially designed to effectively remove welding spatter.
The multiple jaws of the piler are used to pull the wire and install the tips and
nozzles.
#4 Chisel
Normally, chisels are used to cut flat, round, or angled iron and cut sheets of
thick metal. They are also used to remove unnecessary metal from a work
surface by cutting it into small pieces. But in welding, It is used for cutting the
jobs and for cleaning the slag, spatter, and surplus metal from the job after
welding.
#5 Tongs
Tongs are hand tools used by blacksmiths to lift and hold hot weld pieces of
metal. They are usually made of wrought iron or steel and are better than
pliers or vice grips. These are available in different sizes and shapes which
are intended to hold the job while welding.
#6 Cylinder Key
It is used for opening and tightening the spindle valve of the gas cylinder.
#7 Wire Brush
It is used for cleaning the welding surface before and after welding. It consists
of steel wires and is made of stainless steel. Keep in mind that in welding,
always use a brush with stainless steel bristles and a chipping hammer made
of stainless steel.
#8 Clamps
Welding clamps are sheets of metal that temporarily hold two parts of material
tightly together. Welding clamps permit you to securely hold your workpiece,
so the operator will produce a tighter joint.
This makes it easy to run the arc and join the pieces together without worrying
about moving sheets. These types of clamps are generally available in
varieties of sizes and shapes.
#9 Angular Grinder
Angular grinders are commonly seen in metal fabrication and some metal
shops. They are types of handheld power tools attached to consumable stone
discs or blades. These discs spin at high speed to grind, cut or give a smooth
finishing touch to weld metal.
Read Also: All about the different types of grinding machines [PDF].
#10 Spark Lighter
It consists of a shape edges stone piece that produces a spark when it is
rubbed with a hatched cast-iron wheel. It is used for lighting the gas released
from the welding torch.
#11 Try Square
It is an L-shaped measuring instrument. Its blade is usually graduated in
centimeters and the same is used for job measurement purposes. It is also
used for checking the right angles of a rectangular job.
#12 Tip Cleaner
There is a fine hole in the nozzle. The hole may get dirty and even closed
during use. A nozzle edges tip cleaner is used for cleaning the hole, see in the
figure. A tip cleaner may also be used for removing slag from the job after
welding is done.
#13 Files
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These are similar to angular grinders, used to remove rough edges and burrs
from the metal you cut. The file tools are available in various shapes and sizes
which are used for work finishing purposes. Metal files are also commonly
used for all kinds of other metal projects.
#14 Centre Punch
The punch tools are often used to mark holes that must be drilled in
secondary operations, or as gauging marks for bend lines, shearing, spot weld
locations. It is used for marking on a job piece before cutting the same into a
desired shape.
#15 Scale and Weld-gauge
Scale is used for measuring the size of a job and the weld-gauge is used for
measuring the depth of the weld, see in the figure.
#16 Steel Tape
Long jobs are measured by steel tape. It is marked in inches and centimeters
and it is housed in a steel or plastic case. The spring for the assembly helps in
the quick and automatic collection of the tape, as seen in the figure.
Welding Equipments
The equipments used in welding are as follows:
1. Gas cylinder
2. Gas regulator
3. Hose-pipe
4. Welding goggles
5. Welding Helmet
6. Handy gloves
7. Anvil
8. Cylinder trolly
9. Apron
10. Welding torch
#1 Gas Cylinder
Welding gas cylinders are made with thick steel sheets as they have to bear
high gas pressure. Manufacturers supply gas-filled cylinders to the users.
Generally, oxygen and acetylene gas cylinders are used for gas
welding purposes. The two gases are supplied in separate cylinders.
1. Oxygen Cylinder
Oxygen gas can be stored in a cylinder for a long time. The temperature of the
cylinder remains 70° Fahrenheit and the gas pressure is kept at about 2200
pounds per square inch.
The Oxygen cylinder is colored to black and its valve has right-handed
threads. These two points are useful in the identification of oxygen cylinders.
2. Acetylene Cylinder
The acetylene cylinder contains acetylene gas in liquid form. The temperature
of the cylinder remains 70° Fahrenheit and the gas pressure is kept at about
250 pounds per square inch.
Before filling the gas, some quality of dry porous material (charcoal) and then
acetone is filled in the cylinder. Now, acetylene gas is filled in the cylinder at
about 250 pounds per square inch pressure and finally, the cylinder is rotated
for some time.
The acetylene cylinder is colored to dark red and its valve has left-handed
threads; These two points are useful in the identification of acetylene
cylinders. There are also two safety valves that are mounted at the bottom of
the cylinder.
Both cylinders are provided with safety caps. Acetylene cylinders should not
be used in a lying position.
#2 Gas Regulator
For the welding process, the oxygen and acetylene gases reach the welding
torch through gas regulators. There are two main functions of a gas regulator:
1. To maintain necessary gas pressure during the course of welding.
2. To supply the gas to the welding torch at a low pressure. The
regulator’s body is generally made of brass metal.
The gas regulator is available in two types.
1. Single Stage Regulator
It mainly consists of diaphragm, spring, control-valve, body, pressure gauge,
pressure adjusting screw.
This type of regulator has two ports; (i) Inlet – through which the gas at high
pressure enters the regulator from the cylinder, (ii) outlet – through which the
gas at low pressure is pulled to the welding torch through the hose pipe.
The gas enters the regulator under high pressure through the inlet and exerts
pressure on the diaphragm. The diaphragm is supported by a spring which is
also used as a pressure adjusting device with the help of a screw.
The regulator valve and diaphragm reduce the gas pressure and supply the
same to the welding torch through the hose pipe from the outlet.
2. Double Stage Regulator
In this type of regulator, the pressure of the gas is reduced from high to low in
two steps. The device consists of two gas chambers i.e., the main chamber
and the auxiliary chamber. The device has two springs and two diaphragms.
The gas enters the main chamber and its pressure is reduced to some extent.
The gas then enters the auxiliary chamber from the main chamber at reduced
pressure. Here, the gas pressure is further reduced and the same working
pressure is carried through the hose pipe to the welding torch.
#3 Hose Pipe
The hosepipe is the medium through which gas is supplied from the regulator
to the welding torch. Separate hose pipes are used for oxygen and acetylene
gases.
These are made of good quality rubber and are fitted with the help of clamps
in their respective regulators and welding torches. Typically, a black or blue
pipe is used for oxygen gas while a red pipe is used for acetylene gas.
#4 Welding Goggles
Goggles are used for the protection of eyes against any possible bad effect of
the gas flame. Green or blue glasses are used in the goggles which are
capable to protect the eyes from ultraviolet and infra-red radiation of the high-
temperature gas flame.
#5 Welding Helmet
It is an essential type of welding equipment that is considered the most
important piece of personal protective equipment that a welder should have.
This helmet not only protects the eyes and skin from serious sparks, but also
from potentially vision-damaging ultraviolet and infrared rays released by arcs.
#6 Handy Gloves
Welding gloves are tools that protect a welder’s hands from the dangers of
welding. Leather or asbestos gloves are used for the protection of hands
against any possible burn during welding.
These gloves allow the operator to be protected from electric shock, extreme
heat, and ultraviolet and infrared radiation, and also provide abrasion
resistance and increased grip.
#7 Anvil
An anvil is consisting of a strong metal (usually forged or cast steel) with a
flattened top surface upon which another object strikes. An anvil is used for
hammering a hot job as required. It is made of steel so as to have sufficient
toughness, see in the figure. The anvil is used as a forging tool in most cases.
#8 Cylinder Trolly
A cylinder trolly is very helpful for conveying the two gas cylinders from one
place to another for gas welding purposes.
#9 Apron
A leather apron is very useful equipment for protecting a welder’s clothing
against sparks and red-hot particles. It is usually tied to the chest portion of
the body.
#10 Welding Torch
It is also known as a blow-pipe. The instrument is meant for producing the
oxygen-acetylene flame. It is provided with two gas adjusting knobs (one for
each gas). The desired type of flame can be produced by adjusting the two
knobs. Two hose pipes are clamped on the two inlets of the instrument.
Gases are mixed in the mixing chambers and then the mixture comes out of
the welding torch through its nozzle or tip where it is converted into flame with
the help of a spark lighter. The nozzle or tip is made to bear the high
temperatures.
Nozzle’s size depends on the size of its hole and they are replaceable. The
size is marked on the nozzle which indicates the thickness of the metallic
sheets to be welded with that nozzle. There are two main types of welding
torches.