Knowledge base

24 May 2021

Flagship devices of the XQ series by EWM in the Tomsystem offer!

We are pleased to announce that the Tomsystem offer includes the leading EWM MIG / MAG XQ welders: Titan XQ puls Phoenix XQ puls Taurus XQ […]
23 May 2021

TOMSYSTEM – EWM SILVER PARTNER!

We are pleased to announce that Tomsystem has been awarded the EWM 2020 Silver Partner title. It is a great honor for us. Currently, Tomsystem is […]
23 May 2021

INNOVATION AT TOMSYSTEM – WE ARE LAUNCHING A NEW PROJECT

We are pleased to announce that the Tomsystem has started the implementation of a project co-financed by the European Union under the Operational Program Eastern Poland, […]
17 May 2021

INTERNATIONAL FAIR OF WELDING TECHNOLOGY AND EQUIPMENT

Soon, there will be another edition of the International Fair of Welding Technology and Equipment, carried out as part of “Industrial Autumn in Targi Kielce”. The […]
12 May 2021

Tomsystem – EWM Premium Partner 2019

We are pleased to announce that Tomsystem Sp. z o.o. received the EWM PREMIUM PARTNER 2019 award. Tomsystem as EWM’s Premium Partner provides: Comprehensive selection of […]

Soon we will present the references of the TOMSYSTEM company with a description of the implementation for our clients

24 May 2021

Phoenix XQ puls – perfection and ease of use

XQ products from EWM XQ group are undisputed breakthroughs in welding technology. We are pleased to present another model – the Phoenix XQ puls device, which […]
24 May 2021

EWM’s TITAN XQ – welding machine with character

Allow us to introduce the Titan XQ multiprocessing MIG / MAG welding machine. An ideal solution for welding companies, thanks to which welding becomes even more […]
24 May 2021

Taurus XQ – dreams becoming reality

The EWM company has expanded its offer of the most modern devices in welding technology introducing a new model of the Taurus XQ Synergic welding machine […]
24 May 2021

Industry 4.0 in welding

You’ve most probably heard of the term Industry 4.0, recently, meaning the fourth industrial revolution that began in 2010 and turned all sectors of the economy […]
24 May 2021

Collaborative robots – a glimpse into the future of welding

Collaborative robots, i.e. cobots (collaborative robot) are a determinant of the progressive development of robotization in many industries, including welding. When deployed to existing production environments, […]

SUSTAINABILITY, SO MORE GREEN IN TOMSYSTEM

For the TOMSYSTEM team, welding is more than just a process of joining various types of metals. As active promoters of sustainability, we pay special attention to environmental protection issues in every aspect related to the welding process, making our contribution to protect our green planet, significantly reducing the amount of environmentally hazardous waste. We take every opportunity with great pleasure and commitment to protect natural resources from harmful pollution and actively encourage our customers and enthusiasts to do so.

17 May 2021

WHAT DOES WELDING HAVE TO DO WITH FOOTBALL?

Welding enthusiasts and die-hard football fans will surely be interested in the fact that there is a football club made-up of professional… welders! We’re not joking! […]
17 May 2021

MARTENSITIC STEEL LASER WELDING

Martensitic chrome steels are now among the steel grades of the future. They are highly resistant to corrosion, and at the same time have high strength […]
17 May 2021

A DEFICIT OF PROFESSIONAL WELDERS

According to the nationwide report “Occupation Barometer” (developed by the Voivodship Labor Office in Krakow at the request of the Ministry of Development, Labor and Technology, […]
12 May 2021

ForceArc puls – INNOVATIVE WELDING PROCESSES

The latest products introduced to the market by EWM – the leading manufacturer of welding machines which are characterized by very high quality and functionality – […]
12 May 2021

THE WORLD’S FIRST WELDED BRIDGE

The development of welding methods resulted in a huge development of the industry. Poland has achieved world-class standards in the field of welding thanks to the […]
15 April 2021

WHAT WELDING MACHINE YOU NEED TO START YOUR PAINT SHOP?

What welding machine to purchase? This question is probably asked by every welding shop owner… A huge variety of devices on the welding market, a large […]
15 April 2021

PREVENTATIVE MAINTENANCE

Every welding machine operator knows how important it is to service welding equipment. But is preventative maintenance really worth it, is there really a need and […]
15 April 2021

IS IT WORTH PURCHASING THE WPQR EN 1090 PACKAGE?

The WPQR EN 1090 package saves you time and money! Use the EWM WPQR EN 1090 package to create your own welding instructions for the scope […]
15 April 2021

THE MOST IMPORTANT WELDING ACCESSORIES IN THE WELDING PROCESS

The precision of any welding work is determined not only by the person who performs it, but also by the equipment used. With the use of […]
1

What is welding and what are its methods?

Welding is a process of joining two elements that can be made of the same material, but it is not necessary. Sufficient energy must be applied to these two elements to cause the edges to melt and join. Sometimes this is enough and you don't need to add anything to get these elements combined, but in most cases you need to add the so-called binder that will help join elements.

Welding methods:

  • Manual welding with a coated electrode MMA.
  • Welding with the MIG / MAG method.
  • TIG welding.
  • Sub arc welding.
  • Gas welding.
2

What’s welded using the MIG / MAG method?

In the MIG / MAG method, the electric arc glows between a metal electrode in the form of a continuous wire and the welded material. The arc and pool of molten metal are protected by a stream of inert or active gas. The method is suitable for welding most materials. Offered are electrode wires suitable for a variety of metals. The MIG / MAG method is inherently much more efficient than the manual metal arc welding method, in which there are interruptions when the worn electrode is replaced. In addition, there is also material loss as the electrode stumps are ejected. For every kilogram of coated electrodes, approximately 65% becomes part of the junction (the rest is discarded). As a result introducing solid wires and cored wires, this ratio was increased to 80-95%. The MIG / MAG method is a universal method that allows you to obtain the weld gradually at very high speed and in all positions. It is widely used for welding thin and medium-sized steel parts and for welding aluminum alloys, especially when high-performance manual welding is required. The introduced core wires are more and more often used for welding large steel structures.

3

What’s welded using the TIG method?

The TIG method (also known as GTAW - Gas Tungsten Arc Welding) uses a non-consumable tungsten electrode. The electrode, arc and the area adjacent to the molten metal pool are protected from the atmosphere by an inert shielding gas. If a binder is required, the additive material is introduced at the leading edge of the molten metal pool. Using the TIG method, extremely clean, high-quality joints are obtained. As no slag is formed in the process, the risk of contamination of the weld with its inclusions is eliminated, and the finished weld requires virtually no cleaning. This method is suitable for welding almost all metals, and the process can be eithermanual or automated. The TIG method is most often used for welding aluminum alloys and for welding stainless steels, where the uniformity of the joint is critical. It is widely used in the nuclear, chemical, aerospace and food industries.

4

What’s welded using the MMA method?

The MMA method (Manual Arc Welding) means arc welding with a coated electrode. It is the most versatile method of arc welding, allowing you to weld in difficult conditions or in hard-to-reach places. This method uses a coated electrode consisting of a metal core covered with a compressed sheath. As a result of welding with this method, an electric arc is created between the end of the electrode and the material being welded, which can be powered with an alternating current or direct current (negative or positive polarity). A characteristic for this method is the manual movement of the electrode while it melts. The molten metal droplets of the electrode are transferred through the arc to the molten pool of weld metal, forming a weld after cooling. The melting coating of the electrode releases gases that protect the molten metal from the atmosphere. A slag layer is formed at the junction point, which is removed. When the electrode is removed from the workpiece, the electric arc stops and the welding process is interrupted. The MMA method differs from the TIG and MIG / MAG methods mainly in that in the MMA method the electrode is shortened, while in the TIG and MIG / MAG method the length of the electrode remains unchanged throughout and the distance between the holder and the welded element is constant at all the times.

5

What determines the welding units electrical power and how is it measured?

First of all, it should be remembered that the greater the power of the welding device, the greater its ability to weld thick elements. Therefore, one of the most important parameters to be defined is the power of the welding unit, otherwise known as the value of the welding current. The operating costs of the device depend on the amount of power consumed. The lower it is, the lower the costs associated with the consumption of electricity. The electric power of a welding unit depends on the product of voltage and current [P = U * I]. We measure power in Watts [W].

6

What types of welding joints are there?

We can distinguish:

  • Butt Joint Welding – a butt joint is a joint where two pieces of metal are placed together in the same plane, and the side of each metal is joined by welding. A butt weld is the most common type of joint. There are many different variations but are simple to prepare.
  • Tee Joint Welding – these joints are formed when two pieces intersect at a 90° angle. This results in the edges coming together in the center of a plate or component in a ‘T’ shape. Tee joints are considered to be a type of fillet weld, and they can also be formed when a tube or pipe is welded onto a base plate.
  • Corner Joint Welding – similar to tee welding joints. However, the difference is the location of where the metal is positioned. In the tee joint, it’s placed in the middle, whereas corner joints meet in the ‘corner’ in either an open or closed manner—forming an ‘L’ shape.
  • Fillet Welding – fill a round or elongated hole in one of the sheets of the joint with adhesive. They are usually made to strengthen fillet welds when connecting wide elements.
  • Melt-through Welding – formed by melting one of the sheets and fusing into the sheet underneath it. They are usually made to strengthen fillet welds when connecting wide elements.
7

What are the risks associated with the profession of a welder?

According to the information contained in the international safety data sheet, the following threats are identified in the profession of a welder (source – Central Institute for Labor Protection):

  • Electric arc welders are exposed to burns from flying pieces of hot metal.
  • During electric arc welding / cutting, ultraviolet radiation is emitted which may adversely affect the worker.
  • Gas welding poses a risk of fire and explosion from welding gases.
  • Exposure of a welder to welding fumes during work effects their health.
  • The welder / cutter is often working in a forced body position (welding in double tanks, etc.), which can cause back, shoulder, arm and leg pain.
  • The work of a welder / cutter often requires the handling of heavy tools and components, which can cause back injuries.
8

What type work environments may cause accidents during welding?

  • Slippery, uneven surfaces, ladders, platforms – pose threats of slipping, tripping and falling.
  • Electricity – risk of electric shock in the event of malfunctioning electrical equipment (voltage on the exterior of the electric welder, welded elements).
  • Very high temperature of sparks in contact with combustible materials (such as gasoline, oil, paint, wood, acetylene, hydrogen), molten metal drops, hot welded parts – the possibility of burns to hands, face, neck and legs.
  • Metal filings, sparks, acid droplets – the possibility of mechanical injuries to the eyes, face and body.
  • Lower limb injuries, mainly caused by improperly fitted cut or welded elements.
  • Injuries of the upper limbs, caused by haste and inattention while working with sharp and rough elements.
  • Ignition of working clothes caused by unsuitable or dirty, mainly flammable substances.
9

What physicl factors connected to the profession of a welder, may cause negative health effects?

  • Inadequate lighting of the workplace, especially during work in unusual places (narrow corridors, tanks, etc.) - the possibility of eye fatigue.
  • Ultraviolet (uv), infrared (ir) radiation – the possibility of eye damage (cataracts) and skin (sunburn), and the development of skin cancer after many years of exposure.
  • Excessive noise – Possible damage to hearing.
  • An explosion, fire, leaks in the system or gas cylinder (acetylene gas cylinder), damage to the burner or flashback can cause severe burns or death.
10

What chemical factors connected to the profession of a welder, may have negative health effects when welding?

  • Inorganic dust and fumes – possibility of chronic bronchitis and pulmonary fibrosis (pneumoconiosis of electric welders). Dust can cause headache, breathlessness, or respiratory problems.
  • Beryl – the possibility of developing neoplastic changes.
  • Metal fumes (especially zinc) - the possibility of the so-called foundry fever (flu-like state of elevated body temperature).
  • Manganese, cadmium, chemical compounds included in the protective screens (argon, helium, carbon dioxide) as well as chromium, nickel, steel and other metals – possibility of poisoning.
11

What ergonomic, psychosocial and work organizaion factors connected to the profession of a welder, may have negative health effects?

  • Medium-heavy and heavy physical work, performed in a forced body position (standing, bending, crouching), often in small spaces (double bottoms of ships, tanks) - possible pain resulting from overloading the musculoskeletal system.
  • Manual transport of heavy items (tools, cylinders, etc.) - possible back injuries.
12

What are the possible fire hazards when welding?

The most common causes of a fire during the welding process are:

  • Welding sparks.
  • Leaving flammable materials unprotected in the area where sparks are sprayed.
  • No safequard in adjacent rooms through which welded piping systems run.
  • Using inoperative electric welding cable equipment.
  • No water containers for electrode waste.

The cause of a fires during arc welding is the spattering of metal particles, which in contact with a combustible substrate ignite. The greatest risk occurs in workshops where floors are splattered with flammable oils, or where there are dirty rags saturated with solvents and oils.

13

What extinguishers should your welding shop be equipped with?

In places where welding activities are performed, these extinguishers are mandatory:

  • Powder or foam fire extinguishers.
  • Non-flammable tarpaulins – mats.
14

What are the most common health problems associated with welding?

    Welder can face health problems with respiratory and musculoskeletal systems, as well as eyesight and hearing. The most common occupational diseases are:

  • Metallic fever (also known as zinc fever or foundry fever) - is the most common respiratory disease associated with welding. The cause of metal fever is exposure to fumes containing metal oxides, such as zinc, copper, magnesium, iron, manganese, mercury, etc. This disease is often episodic. Symptoms (irritation of mucous membranes, cough, chest pain, headache, fever) usually disappear spontaneously after a few days and do not cause any health consequences.
  • Pneumoconiosis (electric welder pneumoconiosis) - most often caused by iron, tin or barium oxide. This disease usually has no symptoms and most often is detected by chance.
  • Bronchial asthma – usually occurs when a welder uses a variety of welding methods. The most common cause of allergic occupational asthma in welders is exposure to metals.
  • Chronic obstructive pulmonary disease is a chronic disease characterized by an incompletely reversible restriction of airflow through the respiratory tract, which often leads to a permanent reduction in the efficiency of the respiratory system. Chronic exposure to components of welding fumes such as cobalt, aluminum, manganese, titanium, beryllium and cadmium has been shown to accelerate the development of chronic obstructive pulmonary disease and emphysema.
  • Chronic beryllium disease – is a respiratory disease caused by inhaling dust from alloys containing beryllium. The development of the disease takes many years.
  • Hard metal lung disease (cobaltosis) - is caused by inhaled exposure to cobalt. It leads to changes in the lungs in the form of chronic inflammation with interstitial infiltration, the so-called giant cells.
  • Malignant tumors of the lungs - some factors that may be present in the work environment of welders (asbestos, beryllium, chromium, cadmium, nickel) have been classified as carcinogenic to humans. Welders are considered to be at particular risk of developing pleural mesothelioma, a malignant tumor caused by exposure to asbestos.
15

What preventive measures should be taken to eliminate the risks associated with working as a welder?

  • Use special glasses, helmets and face shields to protect the eyes against radiation, dust, metal filings, sparks and respiratory protection, hearing protection, protective clothing and protective gloves.
  • Install effective exhaust ventilation and air conditioning to prevent air pollution and heat stress.
  • Use safe methods of lifting and carrying heavy or bulky loads, and use mechanical devices that facilitate lifting and carrying.
  • Use safety shoes that ensure comfort during long periods of standing work. Use floor mats to reduce leg fatigue. Take breaks from work to rest and exercise to prevent overload injuries to the musculoskeletal system.
  • Check the ladder before climbing it. Never climb an unstable ladder or ladder with slippery rungs.
  • Use hearing protection
  • Check the technical condition of electrical devices before work and have an authorized employee repair any damage and periodically inspect the devices.
  • Regularly inspect gas cylinders and their accessories, paying particular attention to the condition of rubber hoses, valves and cylinders.

EXPERT ONLINE TECHNOLOGY FITTING SERVICES

Coming soon only at Tomsystem – An innovative system of expert online technology fitting services!! Innovative software developed by Tomsystem, enabling an automated process of selecting the technology necessary to perform the welding process. By entering the selected parameters, the user will be able to generate detailed guidance on the equipment and process that guarantees the achievement of the target results. The recommended software based on automated functionalities will ensure a fast and proper selection of welding technology, which is a key element determining the quality of the welded structure.

Details soon...

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