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Tag: welding

Welding techniques: Carbon Arc Gouging (CAG) welding

Our monthly column on welding is back. Today we are talking about CAG welding, also known as gouging.

How does it work?

CAG welding is an arc cutting process used to make grooves and recesses.

It creates an electric arc between the tip of a carbon electrode and the metal that needs to be welded. The electrode is coated with graphite and a copper layer to increase conductivity.

At these temperatures the metal melts and a high-speed jet of air is gusted along the electrode to remove the worked upon area, leaving a clean groove.

When to use Carbon Arc Gouging (CAG) welding?

The CAG process is particularly suitable for removing poorly executed welds and repairing cracks as there is no thickness limit.

Since carbon arc welding does not rely on oxidation, it can be applied to a wide range of metals.

However its versatility and speed results a generally wide and non-precision cut.

Want to know more? Want to know more? Discover our range of engine driven welders by clicking here and follow us on social media to be kept up to date.

Welding techniques: TIG welding

New year… new edition of our monthly column on welding!

Today we are talking about TIG (Tungsten Inert Gas) welding. A technique that is particularly suitable when a high level of aesthetics is required.

How does it work?

Heat is produced by an electric arc between an infusible tungsten electrode and the material that needs to be welded, in an inert gas atmosphere.

The most common gases are Argon and Helium, which are used separately or in a mixture.

Welding is carried out by fusing the edges of the piece that needs to be welded and manually adding the filler material using a welding rod.

Types of ignition

The welding arc can be triggered in three ways:

Scratch Start, when the electrode tip touches the surface, generating a short circuit.

Lift Arc, when the electrode tip, at a very low current level, is placed on the surface and lifted just slightly.

HF Ignition, when the electrode does not touch the surface that is being welded. The electric arc is generated by the high voltage at high frequency on the torch, and it is in this way that a myriad of sparks ionise the gaseous atmosphere between the electrode and the workpiece, triggering a passage of current.

Which metals can be welded?

Stainless steel, aluminium, cupronickel, copper, iron and special alloys can be welded.

TIG welding requires a great deal of manual skill. This is because when using the welding rod the for addition of filler material, one must prevent the electrode from sticking to the surface. Moreover, minimize the risk of contamination of the weld pool by tungsten, especially with the Scratch Start.

Due to the high precision and slow process, this technique is therefore suitable for visible welding on small material thicknesses.

Want to know more? Discover our engine driven welders range by clicking here and follow us on social media to keep up to date.

Genset: security and innovation are tailor made

At Genset we work to meet the specific needs of our customers.

It is from this desire that the MPM 15/400 MSA 400 Ampere was born, an engine driven welder that meets specific requirements for safety and ease of transport.

This product is emblematic to our “tailor-made” approach. Our Research and Design team prioritise your needs, allowing them to create both unique and cutting-edge solutions for you.

It is in this context that, in 2021, we carried out a major order for a high-value customer who has specialised for more than 120 years in the rental and sale of machines such as the MPM 15/400 MSA and equipment for industry, construction, events and more.

Product safety

The MPM 15/400 MSA is equipped with a bunded tank to contain unintentional liquid spills as well as protect the environment. It is equipped with the MSA safety system to work in a safe and controlled environment.

How does the MSA system work?

The MSA safety system allows the operator to stop the unit when leaving the workstation, through the use of a connector and a safety key installed on board.

With this technology, the instrument panel of the welding machine can only be used whilst the safety connector inserted. If you take the connector with you, you can be sure that the unit will be switched off until the operator returns.

What if the connector is lost?

In a special hidden compartment, you may find the emergency key, which allows the unit to be reactivated without the connector, whilst at the same time remaining safe.

The objective of the MSA system is to prevent accidents and injuries due to possible distractions, protecting the safety of workers.

Ease of transport

Ease of transport is, after safety, the second key element of this product, as it has compact dimensions and is equipped with a custom-made trolley with two pneumatic wheels and a drawbar to facilitate handling operations.

Are you looking for a product that perfectly suits your needs?

Contact us for a tailor-made consultation, our team will be happy to contribute to your projects.

Welding techniques: MIG/MAG continuous wire welding

We are back with our monthly column about welding, which describes the main techniques, accessories and materials that you need to know in order to choose the best welding machine suited to your needs.

Today we are talking about MIG/MAG continuous wire welding.

This technique is based on the fusion of a welding wire, generally solid metal, through heat generated by the electric arc.

The wire is automatically fed into the fusion bath under gaseous protection, by means of a torch connected to the positive pole of the welding machine. The wire feeder then conducts the wire from the torch to the workpiece.

Throughout this process, the gas plays the same role as the electrode coating, i.e. it protects against oxidation and allows slag-free working.

What is the difference between MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding?

Depending on the gas protection, we distinguish between two types of continuous wire welding:

MIG (Metal Inert Gas) welding is achieved by using an inert gas that does not participate in fusion, such as Argon or Helium.

MAG (Metal Active Gas) welding, on the other hand, is based on the use of an active gas, such as CO2 or ArCO2 mixtures in different percentages, depending on the material that is being welded. In this case, the gas takes part in the fusion.

How and what may be welded with a continuous wire welding machine?

Continuous wire welding is ideal for carrying out a large number of welds with high filler volumes. It may be used on engine driven welders with electronic welding control.

It is a very versatile technique and rather easy to handle. It is, however, preferable to weld indoors to prevent weathering to take place, stripping it from the gaseous protection.

It is usually used for welding steel, light metal alloys, copper, nickel and titanium.

The equipment is rather bulky and therefore difficult to transport, as the gas cylinder must also be carried.

Want to know more? Click here to find out more about our engine driven welders or write to us for a tailor-made consultation.

The Briggs & Stratton powered Genset range has been extended with a new engine driven welder

The MPM 5/200 IELBN engine driven welder is the new addition to the Briggs & Stratton powered range.

The features

• Lightweight, safe and easily transportable, it is also available with a trolley for effortless handling.

200 Ampere DC coated electrode welding, which may be used as both a generator and welder simultaneously (within the power limits of the machine).  

• It has a 4,5 kVA three-phase and 3,6 kVA single-phase AC generator.

6,6 litre fuel tank which results in two hours’ working autonomy.

• Set up for remote control operation, allowing one to comfortably adjust the welding current from the workstation. Once connected to the front panel connector, the remote control is immediately operational.

The Briggs & Stratton engine

The engine driven welder is equipped with a Stage V XR 2100 petrol engine from Briggs & Stratton, a world leader in the production of air-cooled petrol engines.

It is reliable and fuel efficient, as well as meets the most stringent emission regulations.

For further information please download the product data sheet and do not hesitate to contact us for a tailor-made consultation.

Welding techniques: Shielded Metal Arc Welding (SMAW)

Today we are launching our new monthly column dedicated to welding. It will tell you all you need to know regarding the main accessories, materials and techniques in order to choose the best engine driven welder for your needs. Let’s start with the best known: Shielded Metal Arc Welding (SMAW).

Shielded Metal Arc Welding: what is it?

It is the most common, fastest and cheapest method of welding.

It uses an electrode that is coated with specific materials, which prevents the weld from oxidizing and allows it to stabilize the current arc.

Let’s start with the basics: To begin with, an electrode holder and the material that needs to be welded is connected to the polarities of the welder. The electrode is then attached to the clamp, and when it is brought into contact with the material that needs to be welded, a current arc is produced. In this way, the material that needs to be welded, the coating of the material and the electrode core fuse together.

The different types of electrodes and their electrode coating types:

Acidic (silica, iron silicate): cheap, provides good arc stability.

Cellulosic (cellulose, silicon, manganese): excellent penetration capacity in the material. Suitable for precision work with little slag in the bath.

Rutile (rutile): cheap and easy to store, very smooth welds.

Basic (calcium and magnesium): high purification capacity of the base material, suitable for objects that need to be welded with a greater thickness.

What materials can be arc-welded with a coated electrode?

Almost all materials may be arc-welded, with the exception of lead, zinc, tin, oxygen-reactive and refractory materials.

This process is very versatile but is not recommended for welding joints thicker than 40mm. But we’ll talk about that next time.

In the meantime, follow us on our social to stay updated and find out more in the Engine Driven Welders section, or write to us for a tailor-made consultation.

18/10/2021

Gen Set S.p.A.

Società a socio unico
Via Stazione, 5 - 27030
Villanova d’Ardenghi (PV)
C.F. 10211540157
P.IVA 01470510189