Safety Guidelines
Eye Protection
Always wear proper welding helmet with correct shade lens (minimum #10 for MIG, #11 for TIG). Auto-darkening helmets recommended for convenience and safety.
Fire Prevention
Keep fire extinguisher within reach. Clear area of flammable materials. Sparks can travel up to 35 feet. Have a fire watch for hot work.
Ventilation
Welding produces harmful fumes. Work in well-ventilated areas. Use fume extraction when welding galvanized steel, stainless, or painted materials.
PPE Requirements
Wear flame-resistant clothing, leather welding jacket or apron, welding gloves, and steel-toed boots. Remove synthetic fabrics that can melt.
Electrical Safety
Inspect cables for damage before use. Keep work area dry. Never touch electrode while equipment is energized. Ground your workpiece properly.
Cylinder Safety
Secure gas cylinders upright. Keep away from heat sources. Never drop or strike cylinders. Cap when not in use. Follow proper handling procedures.
Pro Tips
Clean Metal = Good Welds
Always clean base metal with a wire brush or grinder. Remove rust, paint, oil, and dirt from the weld area. Contamination causes porosity and weak welds.
Tack Welding Strategy
Before running continuous welds, tack every 2-3 inches to hold pieces in position. This prevents warping and movement during welding.
Wire Stick-Out Rule
Maintain 1/4 to 3/8 inch wire stick-out (distance from contact tip to workpiece). Too short causes spatter, too long creates unstable arc.
Manage Heat with Technique
For thin materials, use stringer beads instead of weave. Pause briefly between short welds to let metal cool. This prevents burn-through.
Watch the Puddle
The weld puddle tells you everything. A healthy puddle flows smoothly and has slight ripples. Harsh popping means too much voltage. Hissing means contamination.
Gas Coverage Matters
Shielding gas protects the weld from atmospheric contamination. Keep gas diffuser clean and set proper flow rate (20-40 CFH for most applications).
Practice Foot Control
For TIG, use the pedal gradually. Slamming the pedal causes arc flash and spatter. Smooth, gradual adjustments produce consistent welds.
Post-Weld Inspection
Let welds cool naturally (no water quench). Inspect for cracks, porosity, and undercut. A good weld has uniform bead width and proper tie-in at edges.
Quick Reference Chart
MIG Settings by Thickness
| Thickness | Voltage | Wire Speed |
|---|---|---|
| 1/16" | 17-18V | 150-180 IPM |
| 1/8" | 19-20V | 200-250 IPM |
| 1/4" | 21-23V | 280-350 IPM |
| 3/8" | 24-26V | 400+ IPM |
Lens Shade Guide
| Process | Min Shade | Recommended |
|---|---|---|
| MIG (mild steel) | #10 | #11 |
| TIG (low amp) | #9 | #10-12 |
| Stick | #10 | #11-12 |
| Plasma Arc | #11 | #12-14 |