Professional welders and craftsmen know the importance of mathematics in welding. It is used for calculating the connections for metal frames and how to make joints and welds at precise angles. Welders who are good at math can work on precise, complicated projects.
Math skills allow welders to complete more projects and increase their productivity. Good mathematical skill also allows them to prevent mistakes and inaccuracies that would otherwise ruin their project.
In this blog post, we carry out a detailed analysis of how welder can use math to improve the outcome of their welding tasks.
Mathematics in Welding
You will not be able to get very far in welding without a moderate understanding of mathematical calculations and measurements. Math is used to accurately measure, cut, and fit metal frames onto other materials. All of it is based on the calculation of fractions that may need to be converted to decimals. Things get complex when you apply that to measurement system based on yards and feet.
You need math even for the simple process of figuring out how big of a plate you can fit on a rig or what angle of a bevel you should make on a frame to connect your sheets without causing problems.
Math can be a difficult subject especially when it comes to using geometrical shapes, decimals, and fractions. However, all of these mathematical skills are useful, even necessary, in welding. If you are working as a welder or thinking about joining the profession, then you are going to need a lot of mathematical skills, particularly in geometry, area and angle measurement and trigonometry.
If math wasn’t your forte in high school, then don’t worry. A good welding training program will give you all the necessary mathematical skills that you need to succeed in the profession. It is never too late to learn and you don’t need an advanced level course. Even a basic understanding will do a lot of good and improve your welding significantly.
Importance of Math for Welders
Suppose you are working on a project to fit a metal frame on the second-floor window of a building. Without mathematical calculations or measurements, you would need to go up and down the ladder several times to find the correct size of the frame before you can weld it on. By using math, you can simply calculate the correct size and angle of the window by measuring the size of the frame.
There are many welding projects that require mathematical calculations. Every cut that you make must have been previously measured for accuracy or you could end up wasting the plate. When you are connecting two pieces together, they must be held at the correct angle to form the right shape. Even the weld itself must be made at an angle that forms a sturdy and secure meld.
Mathematics comes in handy regardless of your welding industry. Whether you are working in pipe connection, construction sector or indoor furnishing, you need to have a fundamental understanding of mathematical computations. The skill is also useful when you are using blue prints. Every type of welding blue print makes use of mathematical measurements and numbers to build structures.
Without mathematical skills, you would be very restricted in the complexity of welding projects you can complete. There are five main areas of math that are crucial for welders; fractions and decimals, size and area, geometry and trigonometry and algebra.
Fractions and Decimals
Fractions and decimals are the building blocks of welding mathematics. Almost every blueprint you see will have calculations based on fractions that will need to be converted to decimals to get accurate weld points. As a general rule of thumb, you should be able to correctly convert most basic fractions to decimals without needing to get the calculator.
For example, a ½ inch in fraction means one half of an inch or 0.5 inches on the scale. A fraction of ¼ would equal a quarter and comes up to 0.25 inches precisely.
Things begin to get more difficult when fractions start getting more complex. . A measurement of 1/5 of an inch is a fifth of an inch and calculated as 0.20 inches. A measurement of 3/5 is three fifths and calculated as 0.60 inches.
When you are working on a project with precise calculations, you do not want to be going for the calculator all the time. You should be able to figure out exact calculations in decimal, simply by looking at the blueprint on your fingertips.
Area and Size
Experienced welders spend the majority of their time making calculations, measuring up different materials and sheets of metal. The tempilstick, fillet gauge, and protractor are their most important tools. You will often find welders set up a project for hours before they light up the arc even once.
In most cases, welders use a standard fillet weld gauge or tempilstick to verify that the size of their metal frames matches the specifications on the blueprint. The gauge may not measure the metal size to its exact requirement in inches, but it can still be used to verify that a specific size has been acquired. A standard set (as shown below) is ideal for making calculations.
A special larger gauge may also be used for bigger projects that go beyond regular work. If you need to connect different legs of metal together, a variety of protractors can be used that help you make precise cuts and welds for angled joints.
Lastly, you will also need to measure the weight of your metal frames and legs to ensure you do not put too much stress on the base of the structure.
Generally, you will need to make the following types of size calculations for your welding projects.
- Calculation of welding volume – This type of area segment calculation identifies the rounded reinforcing-cap that is placed on a weld joint.
- Calculation of the pounds of steel needed to reinforce a joint effectively.
- Measurement of the amount of material required for a welding project.
- Estimation of the width of the material for a project
Geometry is essential to welding. Several welding projects require you to understand, calculate and measure welds at different angles accurately. Moderate knowledge of geometrical measurements will make it easier for you to connect metals together while advanced knowledge will make it possible to work on complex projects.
Welders also use geometrical knowledge for calculating the length and size of various shapes and calculate the radius, diameter, and circumference for pieces that have a round shape.
In order to use geometrical angles, welders will also need to have the right drafting tools such as triangles. The triangles make it easier to connect 90, 45 & 60 degree angles together. A compass is also used for precise measurements and calculation of points between different angles. Both tools are helpful when creating joints and help ensure that they’re square. They can also be used to determine the radius, diameter and circumference of a circle.
Speaking of angles, welders must also possess a good understanding of trigonometry for creating angled structures. Trigonometry helps welders determine the area of the weld and the angle it should be created at for handling pressure under various environmental conditions.
Trigonometry helps welders determine the strength of the weld and how joints should be made to ensure that they will not break with usage. The welder can test the strength of the joint without breaking it by applying module testing methods such as ultrasonic waves based on tangents, signs and cosigns. Testing methods help the welder determine imperfection in the weld and adjust it to create a durable structure.
Trigonometry is one of the more complex mathematical skills and takes time to master. It can be difficult to understand it if you aren’t already good at geometry. The good part is that you can learn and improve your understanding of angled joints by taking a course in trigonometry.
Algebra and Formulae
The algebraic calculations are used to shape projects, calculate material strength and determine angles for welding. Algebra is usually used a lot in the design process. Architects, construction engineers and designers rely on formulae and calculations to create theoretical structures and shape the product before welders get down to putting it together.
Knowledge of algebra and formulas need not be restricted to designers or engineers alone. Experienced welders also read mathematical formulae so that they can carry out several critical processes required for the completion of welding projects. Welders use algebra for the following.
- Calculate shapes, size, and volume for welding sheets and legs
- Determine the pressure, angle, and volume of gases to use for the arc
- Figure out how changes in temperature will have an effect on pressure
- Recreate shapes and weld structures
How Math Can Solve Your Welding Problems
All types of welding projects rely on mathematical calculations to create an accurate and precise final product. Everything from start to finish is coordinated and completed with strict adherence to mathematical standards. Whether it is the measurement and weighing of the material, determination of the gas pressure and angle of the arc or the duration of the meld, every part of the whole process is strictly completed in accordance with calculations.
There is no guesswork and neither there should be when welding unless you are working on an experimental basis to try out something new. You can work on a project and complete it from start to finish by strictly following the instructions on the blueprint that should tell you everything about how to do a great job.
As any experienced welders will tell you, welding is no longer a mystery but all about engineered, mathematical science applied with perfection. Today, the body of knowledge and mathematical data in welding is quite deep and very helpful, especially for beginners. When you are new and just setting out on your welding journey of discovery precise mathematical calculations and formulae will be very useful to help you build a strong knowledge base.
Welding Wire Melting Point
Every type of welding job requires a specific amount of melted wire that must be deposited in the correct location to connect two pieces of metal. Welders, and by extension manufacturers, are always trying hard to find the most efficient manner of doing this.
There are a number of factors that must be considered for depositing metal into a weld efficiently. The proficiency of the welder and electrical efficiency of the wire are major factors to consider. Additional variables include the design and angle of the welds and layout of the welding machine. The final efficiency of the weld is an aggregate of all the factors that go into melting the wire. The melting rate of the wire can be calculated with the following formulae.
A x Amps + B x Wire Stick Out x Amps2 = Wire Melting Rate
Both A and B are constants and their values are taken from the type and size of the wire.
The electrons move from the negative terminal to the positive. The cable connects to the negative terminal for MIG welding and the gun connects to the positive terminal.
The current enters the welding wire just at the end of the contact tip as a little dot. It flows to the end of the wire to create the Arc. The current heats up when it travels down the length of the wire to the arc. Since there is only a small distance from the tip of the wire to the arc, the whole wire doesn’t melt or explode. The temperature generated by the wire can quickly reach temperatures up to 5000 degrees Fahrenheit.
The negative electrons on the wire create energy that melts the wire and deposits it on the joint in the shape of a puddle.
The Numbers behind the Welding Arc
The stick electrodes that generate the arc come in various sizes and diameters. They have varying recommendations for amps based on the table shown below.
As evident from the table, welders can tell the diameter and thickness of the welding stick to use for best results.
The formula for wire penetration is given as,
The Formula: Wire Penetration
K x [Amps 4 / (Travel speed, ipm x Volts 2) ]0.333
K is constant.
Here are the general rules of thumb to follow:
- Depositing a good amount of welding metal is just one part of the formula for creating efficiency. If the heated metal doesn’t penetrate inside the target material and just deposits on the surface, then the whole process will be in vain and the joint will not be very strong.
- Increasing the volts and travel speed will decrease metal penetration if the amps remain constant. Higher voltage can cause the Arc to get bigger and reduce the force of the arc required for penetration.
- Make sure you follow the simple rule of mathematical division. If the upper number in the formula increases while the lower number does not change, then the result will grow bigger. If the upper number remains the same and the lower number increases the result will shrink.
- Make your electrode calculations accurately. Amps that you put into the equation play a big role in welding. In the formula, t is raised to the power of 4.
- Note that the travel speed is not raised by any power because it simply does not have the same result as amperage.
Welding is all about calculation and measurements. If things go wrong, the solution may not always be that simple. There are plenty of variables to consider and welders can make changes to adjust the end result.
If you are looking to improve the efficiency of your welding operations then consider using more mathematical equations and calculations into your design process for better quality results.