ALL ABOUT MORPHIC WELDING SOLUTIONS
Arc, TIG, MIG welding – Morphic Welding Solutions is owned and run by Paul Whitton. He has experience in the welding, engineering and construction industry. Offering services in all categories of the industry. Being a mobile onsite welding service and have worked for numerous construction companies in and around London. Covering areas like Buckinghamshire, Berkshire and Surrey. We are CSCS compliant to be able to access and gain access to construction sites and supply an up to date Health and Safety Method Statement before commencing work on site. Offering 240v welding and TIG machines that comply with Health and Safety regulations.
Our services are within an 80 mile radius from Staines including London and surrounding areas. We have extensive knowledge and specialize in welding most steels including stainless steel. Together we also offer an on site metal fabrication services.
CUSTOMER BASE
Customers are based around Surrey, Buckinghamshire and as well as customers in and around London. We’ve worked on various welding projects such as steel and stainless steel handrails to gates and fencing within London estates. Services done – such as Stainless steel piping for flues, and stainless arc and TIG welding for places like the 02 Arena. Companies we have done work for – Royal Mail, Darwin Group and O2 Arena.
BUSINESS APPROACH
Together we provide businesses with a risk free approach and will bring portable welding equipment to your premises. We can assess work to give an estimate of the expected time for completion. We can also give an idea of the cost involved.
Our expert staff ensure clients the results they need to achieve in the shortest possible time. Using arc welders for majority of the work is easier to set up therefore keeping setup time to a minimum. This also allows lower costs. Arc welders are a lot lighter therefore easier to maneuver around a construction sites or hard to get places saving on time which saves our clients money. A cost saving approach and attitude is to get the best results for customers. Basically good word of mouth is better than any form of advertising and through our experience we have found a good service allows for consistent clients and therefore consistent work for us.
CLIENT NETWORK
Lastly we have a growing network of clients, located throughout the UK, including Royal Mail, Darwin Group, 02 Arena and variety of big and small clients based in London and surrounding areas.
SERVICES WE OFFER
We offer steel welding repairs, modifications, alterations. Stainless steel and cast iron repairs in and around London and surrounding areas such as Buckinghamshire, Berkshire and Surrey. We also have suppliers that are cost effective and reliable for all kinds of steel such as F.H. Brundle or IMS Steel.
We have a motto all jobs have no issues just resolutions so call us now and lets resolve together your requirements.
THE DIFFERENT TYPES OF WELDING
ELECTRIC ARC WELDING
What is arc welding?
Arc Welding is the process of joining metal to metal with the help of an electric arc hence the name “Arc Welding”.
The arc is used to create intense heat and this heat is used to join the metals together. Then the heat is brought in between two metal pieces and due to the heat generated, the metals melt and when it cools a strong welded joint is formed.
Power source used in arc welding is electricity. The electric current used may be either direct (DC) or alternating (AC). The welding region is protected by some shielding gas, vapors or slag. This shielding gas protects the weld area from atmospheric contamination. Then the welding process can be manual, semi-automatic or fully automated. It uses consumable or non-consumable types of electrodes for the welding purpose. This type of welding was invented in the late 19th century. In the World War II, it becomes commercially important in shipbuilding. Nowadays it is used in the fabrication of steel structures and vehicles.
HOW ARC WELDING WORKS
You need to connect your welder to an electric power source ( AC or DC). Then you must keep the welding rod 2-4 mm away from the base metal and this is when the welding starts. You need a spark or arc to start the welding process. To start this you need to start it in-between the base metal and electrode. When you start welding you need to follow the molten metal and stay with the pool of molten compound. Once you stop it will solidify. After its solidified it forms a strong bond in between the two metal pieces. Shielding gas or flux is there to assist you in protecting the the molten metal or weld from atmospheric contamination. After you’ve completed the welding process you can cool the metal down by dipping it in appropriate coolant. It can also be left for air cooling. This is you arc welding.
THE ADVANTAGES OF ARC WELDING
Compared with many other formats:
- Arc welding is one form of keeping your costs down. Also the process often requires less equipment in the first place because of the lack of gas needed.
- Materials for arc welding are very easy to transport.
- Works on dirty metal.
- Shielding gas in windy and bad conditions isn’t necessary. The processes can be completed during wind or rain, and spatter isn’t a major concern.
- Shielding gas in windy and bad conditions isn’t necessary. The processes can be completed during wind or rain, and spatter isn’t a major concern.
THE DISADVANTAGES OF ARC WELDING
There are a few reasons why some people look to other options beyond arc welding for certain kinds of projects. These downsides can include:
- More waste is generally produced during arc welding than many other types, which can increase project costs in some cases.
- Operators of arc welding projects need a high level of skill and training, and not all professionals have this.
- It can be tough to use arc welding on certain thin metals.
MIG WELDING
Welding process of MIG is an arc welding process in which a continuous solid wire electrode is fed through a welding gun and into the weld pool, joining the two base materials together. A shielding gas is also sent through the welding gun and protects the weld pool from contamination. In fact, MIG stands for metal inert gas. The technical name for it is gas metal arc welding (or GMAW), and the slang name for it is wire welding.
The process enables the artist, farmer/rancher, motorsports enthusiast or DIY welder to make most types of fabrication and repair welds on material from 24-gauge up to 1/2-inch thick. In addition to flexibility, many people turn to MIG welding because they’ve heard that it’s an easy process to learn. Some claim it’s no harder to use than a glue gun. While it’s not quite that simple, it is true that most people can become competent MIG welders by following some basic advice.
PREPARATION OF THE METAL
Unlike stick and flux-cored electrodes, which have higher amounts of special additives, the solid MIG wire does not combat rust, dirt, oil or other contaminants very well. Use a metal brush or grinder and clean down to bare metal before striking an arc. Make sure your work clamp connects to clean metal, too. Any electrical impedance will affect wire feeding performance.
To ensure strong welds on thicker metal, bevel the joint to ensure the weld fully penetrates to the base metal. This is especially important for butt joints.
WIRE SELECTION
For steel, there are two common wire types. Use an AWS classification ER70S-3 for all-purpose welding. Use ER70S-6 wire when more deoxidizers are needed for welding on dirty or rusty steel. As for wire diameter, .030-inch diameter makes a good all-around choice for welding a wide range of metal thicknesses in home and motorsports applications. For welding thinner material, use a .023-inch wire to reduce heat input. For welding thicker material at higher total heat levels, use .035 inch (or .045-inch wire if it is within your welder’s output range).
GAS SELECTION
A 75 percent argon/25 percent carbon dioxide blend (also called 75/25 or C25) works as the best all purpose shielding gas for carbon steel. It produces the least amount of spatter, best bead appearance and won’t promote burn-through on thinner metals. 100 percent CO2 provides deeper penetration, but also increases spatter and the bead will be rougher than with 75/25.
ARC AND MIG PREPARATION
1STLY we need to look at our welding Machine Amperage Settings. When setting the amperage too high on your welding machine, you will get what is called “undercut”. Under-cut weakens the weld because it eats into the welded material surface, reducing the structural strength of the material. This is more noticeable when welding thicker metal plates together.
You will quickly notice if your amperage setting is too high when welding thin metal plates because it will melt the material away.
However, if you move along quickly using a high amperage setting, you can get a very good weld depending on the situation. Also lingering around in the same spot will introduce too much heat and melt the material away creating an untidy weld.
TIG WELDING
Definition – TIG is another name for gas tungsten arc welding. The aircraft industry created it to weld magnesium in the 1930s and 1940s. Ideally the process works like this: the welder makes an arc between the base metal and the non-consumable tungsten electrode, a type of electrode that does not melt. At the point where the arc hits the base metal a molten weld pool forms. A thin wire of filler metal is slowly handfed into the weld pool, where it melts. All the while, an inert shielding gas protects the tungsten electrode and weld pool from oxygen contamination. No fluxes are used. The finished product is a sound, slag-free weld that shares the same corrosion resistance properties as the parent metal.
WHAT IS TIG WELDING FOR
This welding application can be used for more metals than any other type of process. For this reason, a variety of industries rely on TIG welding. It is used in the construction of spacecraft and airplanes in the aerospace industry. Auto manufacturers use TIG welding on fenders for its anti-corrosive properties. TIG welding is also widely employed in auto body repair shops. Artists appreciate the excellent quality of TIG welds using them in sculpture welding.
ADVANTAGES AND DISADVANTAGES OF OTHERE WELDING METHODS
One of the greatest advantages of TIG welding is the amount of control it allows. A welder can control heat and amperage with precision using a foot or thumb remote control switch. The welding wire is thin, which adds to the control. As a result, this is good for projects where detailed designs or curves are required on the base metal.
Since the TIG torch uses low amperage, the process works well on thin pieces or metal. The combination of the low amperage and remote control switch allows welders to quickly switch from working on thin pieces of metal to thick ones. This makes it a versatile process. Since no fluxes are used and it’s possible to produce a low-profile weld bead, the weld is clean and free of slag. Only a small area of space separates the arc of the flame from the base metal, so this welding process requires a high level of focus and hand-eye coordination. Performing this welding technique requires skills and patience because the process can be time consuming. Despite this, welders can overcome challenges with training and practice.
THE ADVANTAGES OF OTHER WELDING METHODS
Reasons why some people look to other options beyond arc welding. These downsides can include:
Lower efficiency – more waste is generally produced during arc welding than many other types, which can increase project costs.
High skill level – operators of arc welding projects need a high level of skill and training.
Thin materials – it can be tough to use arc welding on certain thin metals.
THE ADVANTAGES OF ARC WELDING OVER OTHER WELDING METHODS
Advantages to using arc welding compared with many other formats:
Cost – equipment for arc welding is well-priced and affordable, and the process often requires less equipment in the first place because of the lack of gas.
Portability – these materials are very easy to transport.
Works on dirty metal.
Shielding gas isn’t necessary – processes can be completed during wind or rain, and spatter isn’t a major concern.
WELDING SAFETY PROCEEDURES
Before we start any welding we need to have all our Health and safety checks.
When welding you need to wear certain safety equipment in order to not injure yourself and others around you.
Always make sure to have good ventilation around your working area. Ensure your working area is shielded off with welding curtains or shields to prevent arc flashing and protection for others in the area around you
Check to see you have the correct fire extinguishers available before starting work. You must wear the appropriate protective clothing at all times to prevent ultra violet ray burns, heat exhaustion, heat burns, welding helmet for eye protection.
Look over all your equipment making certain it is in good working order with no exposed loose wires or defective equipment. Don’t work in wet conditions. Wear the appropriate PPE. It is standard practice to use 110v welding equipment in majority of working places.
Telephone: 07974 409 374
Mobile: 07974 409 374
Email: morphicstudio@yahoo.com