Welding Machine Operation Guide: Safety and Efficiency Tips for Beginners

Pre - welding Preparations

Site and Equipment Inspection

1. Work Site: Ensure that the welding site is well - ventilated to avoid the accumulation of harmful gases. Clear flammable materials around the site and maintain a safe operating space of at least 2 - 3 meters.
2. Welding Machine Inspection: Check whether the power cord of the welding machine is damaged and if all connection parts are secure. Examine if the welding cable shows signs of aging or damage. Verify that the adjustment knobs can properly adjust parameters such as current and voltage. Ensure that the ground wire connection is reliable, and the grounding resistance should be less than 4 ohms.
   

II. Key Points of Safe Operation

(I) Prevent Electric Shock

1. The welding machine must be reliably grounded. Using it without grounding is strictly prohibited. During operation, avoid touching the live parts of the welding machine, such as electrodes and cable connectors.
2. Keep the work area dry and avoid operating in a humid environment. If it is necessary to replace the electrode or perform equipment maintenance, be sure to cut off the power supply first.

(II) Prevent Fire and Explosion

1. Equip appropriate fire - fighting equipment near the welding operation area, such as dry - powder fire extinguishers and carbon dioxide fire extinguishers, and ensure that operators are familiar with their usage methods.
2. Welding is strictly prohibited in an environment with flammable and explosive gases or dust. For containers that have contained flammable and explosive substances, they must be thoroughly cleaned and replaced, and can only be welded after passing the inspection.

(III) Avoid Harm from Harmful Gases and Smoke

1. Try to choose a well - ventilated place for welding. If conditions are limited, local ventilation equipment such as exhaust hoods and ventilation ducts can be used.
2. When performing long - term welding operations, wear a standard - compliant protective mask to filter out harmful gases and smoke.
   

III. Efficient Operation Skills

(I) Welding Parameter Setting

1. Welding Current: Select an appropriate current according to the thickness, material, and welding position of the workpiece. Generally, the thicker the workpiece, the larger the required current. The current can be appropriately increased for flat welding, while it should be reduced for vertical welding and overhead welding. For example, when welding a 3 - mm - thick low - carbon steel plate, the flat - welding current can be set at 100 - 120A, and the vertical - welding current at 80 - 100A.
2. Welding Voltage: The voltage needs to be matched with the current. If the voltage is too high, the weld will be wide with a shallow penetration; if the voltage is too low, the weld will be narrow with a large penetration. Usually, the voltage is adjusted between 18 - 24V, and the specific value needs to be determined according to the actual welding effect.

(II) Welding Techniques

1. Linear Oscillation Method: This method is suitable for the flat welding of relatively thin workpieces. The welding rod moves in a straight line along the welding direction at a uniform speed, resulting in a narrow and neat weld.
2. Zig - zag Oscillation Method: Commonly used for the welding of medium - thick plates, the welding rod makes a zig - zag swing. The swing amplitude is adjusted according to the thickness of the workpiece and the requirements of the weld, which can increase the width of the weld and make the weld formation beautiful.
3. Crescent - shaped Oscillation Method: Similar to the zig - zag oscillation method, but with a larger swing amplitude and a slight pause on both sides. This can ensure good fusion at the weld edges and is suitable for the welding of thick plates and important structures.

IV. Post - welding Work

1. After welding is completed, first turn off the power supply of the welding machine. After the equipment cools down, clean the work site and properly store the welding tools and remaining materials.
2. Check the quality of the weld. If there are defects such as pores, cracks, or lack of penetration, analyze the causes and repair them in a timely manner. For important welded structures, non - destructive testing methods such as ultrasonic testing and radiographic testing can be used to ensure that the welding quality meets the requirements.