Melting temperatures of less than 850º (*depending on the filler metal) are reached when welding copper pipes with aero-butane blowtorches, so the use of 1100º flameproof blankets is recommended, as neither higher thermal radiations nor splashes are produced with the welding process mentioned.
The action field of fumes extraction systems with filter installed in a fixed support is limited to the maximum dimensions of the suction arms installed. Therefore, the largest coverage length of the unit is 8 metres, 4 metres with flexible arm and another 4 metres with the relative extension
The products, according to standard EN 1598, absorb harmful UV, causing inflammation of the cornea, and blue light, which can cause irreversible harm to the retina, allowing the passage of light beyond 560 nm. The infra-reds are not harmful at two metres from the emission source, which is the ideal distance between the curtain and the welding point.
Answer: 2 metres
Products according to standard EN 1598 absorb the harmful radiations that represent a danger for people who are on the outside, even though they are semi-transparent, therefore looking through it represents no risk.
Answer: There is no danger.
The quality tests that are carried out on the optics of the electronic shields are registered, according to standard EN379, with three figures that are silkscreen printed on the inside of all the masks (for example 1/2/1).
• The first digit: Optical class of the filter. Where 1 is the best score and 2 the worst.
• The second digit: This indicates the diffraction. The angle that the light acquires when it crosses the filter. Where 1 is the highest assessment and 3 the lowest.
• And the third digit: Uniformity of the dark tone. 1- uniform darkening on the optical surface. 2- if slight transitions are noticed. 3- in the worst of the cases.
Gala Gar designs and manufactures safety valves against gas and flame flashback for the most commonly used gases in welding and cutting, namely: Acetylene, Propane, Methane, Natural Gas and Oxygen.
These values satisfy two functions: extinguish combustion and stop the gas from passing after a flashback has occurred. Thermal valves also incorporate a gas closure and tripping system when the valve heats above 230ºC.
Gala Gar manufactures safety valves with different types of threads.
There are safety valves for blowtorches, for pressure regulators and for hoses. Of all of these, the only ones that are completely compulsory are the ones that are placed in the pressure regulators. All the others, although not compulsory, are recommendable to protect the hose and the welder.
No special maintenance is required but the safety devices must be verified after each known incident and, in any case, at least once a year. The annual verification must be carried out by the manufacturer, dealer or expert appointed.
Discover the wide range of safety valves offered by Gala Gar.
Yes, we have welding, cutting and heating blowtorches with special dimensions, of one, two and even 3 metres. For example, for less accessible places, larger pieces, special length cutters are used, such as our 1.5 m “H” cutter blowtorch. As we are manufacturers, the flexibility of this process and the knowledge of the product enable us to adapt to our customers’ specific needs.
This does not depend on the cutting tips or on the pressures that the work is carried out at.
There is another factor, too, that is not controlled, which is the fact that the user opens the bypass valves of the torches.
Los sopletes que se usan para gas natural, propano, butano, es obligatorio por Ley que estén homologados por el Ministerio de Industria.
It is impossible to say how they affect them according to the type, though it is true that the torches that use a mixer-injector system are much more likely to suffer these flashbacks.
Those that make the mix in the tips do not usually have flashbacks or these are minimum. The degree of deterioration depends on the work pressures and on the time that the torch is exposed to the flame on the inside. In extreme cases, they may end up useless. If, when the flashback occurs, one of the gas bypass valves is immediately closed, serious damage does not usually occur to the equipment.
Las mangueras que estén en uso, se les realizará una inspección visual, y se verificará que no hayan fisuras, grietas o abombamientos, si está OK se sustituirá al año de su fabricación, y si las hay se sustituirá inmediatamente. Las mangueras que no se hayan usado todavía, se les realizará una inspección visual, si están OK se sustituirán a los 3 años de su fabricación y sino se sustituirán inmediatamente (recomendación hecha por el fabricante)
• Single Expansion is adequate when the gas is used for short periods of time.
• The output pressure increases as the pressure in the cylinder decreases, as with the passing of time less pressure is exerted on the rod of the valve. Frequent adjustments must be made to maintain a constant output pressure.
• Ideal for working at very low pressures
• As the difference in pressure between the intermediate pressure chamber and the low pressure chamber is not so high as in single expansion (high-low) it permits working for longer periods of time as it is not necessary to make adjustments to maintain a constant output pressure.
This saving is due to the reduction of the pressure at which the process receives the gas. This reduction is between 0.2 and 0.6 bars, but it always maintains the quantity of gas necessary for a top quality process. What happens in the process is that when the gas is cut off in the welding process, there is a considerable increase of pressure on the hose and the pressure regulator chamber and therefore, also on the accumulated gas.
This gas that is pressurised by traditional equipment at 3-4 bars, is unnecessarily provided when the welding starts again, giving rise to flow peaks of 5 or 10 times the regulated flow. The mission of the GasFree regulator is to reduce this increase in pressure and therefore the consumption of the protection gas. The reduction of the consumptions mainly depends on the stops and starts that are carried out during the welding process. In the case of spot welding, up to 60% saving can be obtained, whilst in the case of longitudinal beads, about 25% saving can be obtained
NO, the thread of the 200 bar cylinder would be 21.7 x 14 h and for 300 bars it would be W30x2,
Yes, we have different couplings, depending on the gas and the standard applied for each country. For example, for Costa Rica we incorporate CGA-320 type couplings. It is another example of our flexibility as manufactures of regulators.
The same ones that are manufactured for 200 bars can be used for 300 bars; it is only necessary to adapt the input coupling in agreement with the new standard ISO 5145. Therefore, they have a different reference.
Answer: Yes, but we must request the relative reference.
1. Keep the wires free from dust, grease, impurities and humidity. The metal dust adheres easily to the wire on the aluminium reels, and may even saturate the cable of the torch giving rise to the appearance of problems. To prevent this, the feed system must be cleaned regularly maintaining the wire in the conditions recommended by the manufacture.
2. Use different diameter fillers, whenever possible, to reduce the derived feed problems.
3. Use of Push-Pull torches. They include a feed system in the torch casing, which is synchronised with that of the equipment, so that a co-ordinated "push and feed" job is carried out minimising the feed problems. The use of this type of torch is recommended for lengths of over 6 metres.
4. Reduce the actual torch resistance:
1) Length reduction.
2) Neck shape: the straighter, the better.
3) Replacement of the cable with graphite or Teflon.
5. Use of "U" feed rollers and verification of the state of the pressure rollers, which with use, may suffer wear and generate feed problems.
6. Excessive pressure of the clamping knob will be harmful for the system as we run the risk of squashing the wire, increasing its diameter in one of these axes and increasing the resistance on the cable.
7. We must adjust the cable to the diameter of the wire used in the welding and decrease the distance between the exit from the roller and the cable. If this distance is great, the wire bends and breaks.
8. The end of the cable must be brass to prevent the heat from the pistol burning the Teflon sleeve, permitting the distribution of the current along 100 mm, thus avoiding current concentration at the contact tip. Possible energy concentration in the wire will produce short circuits that will slow it down when it comes out of the pistol, producing jamming in the entry of the cable and the rollers.
9. Due to the aluminium dilation coefficient, almost double that of steel, when the wire heats at the contact tip, the diameter increases by a greater proportion, so the diameter of the hole of the contact tip must be bigger, with a slightly greater tolerance than for steel. Therefore, the use of special contact tips for this metal is recommended.
The process can be used in the majority of metals and the range of wires in different alloys and applications is almost infinite. Its flexibility is the most representative characteristic of the MIG/MAG method, as it permits welding low alloy steel, stainless steel, aluminium and copper, in thicknesses above 0.5 mm and in all positions. High productivity and ease of automation place it directly in the automobile sector. The procedure is commonly used in thin and medium thicknesses, in steel products and aluminium alloy structures, especially where a high percentage of manual work is required
Coolant liquid in welding is a very important consumable for the machine to work correctly, to avoid breakdowns and therefore, for greater productivity. At Gala Gar, we have 10 litre bottles (Ref: 39200094) and we receive a large number of questions about this product, some of the most common being listed below:
- Can our liquid be used for any equipment?
Yes, regardless of the make of the equipment.
- What benefits does using this liquid provide?
Reduction of heat caused by the welding process, elimination of calcareous residues and other sediments that spoil the mechanical elements, such as pump or pipes, and lubrication of all the mechanical elements of the recirculation system, thus preventing the metal parts from rusting.
- What problems can arise from not using liquid or not using the right liquid?
Blockage of pipes, problems with the pump derived from scale, sedimentations; in the short term, incorrect operation of the machine and in the medium term, faults in the machine.
- Can water or distilled water be used instead?
Water never, because it is a fluid that transmits electricity, and during welding, an electrical current could circulate through it, generating a descaling effect of the consumables due to electrolysis. With respect to distilled water, it reduces the problems we have mentioned in the previous answer but it does not effectively reduce the heat of the pipes through which it circulates, causing rapid heating of the liquid and therefore reducing the durability of the components. Thus, the use of liquids that do not transmit electricity (dielectric) are recommended, preventing premature deterioration of the torch components.
If you need further information, please contact us.
When aluminium is cut with plasma equipment, the cutting area becomes rusty and a porous edge appears whose volume is greater than the material thickness.
It is clear that there are high definition cutting systems on the market such as the laser, which have exceptional cutting qualities, but in general industry, the admissible tolerances enable quality solutions to be studied without having to make high economic investments.
We must remember that plasma cutting technology is not new on the market, as it has been used for many years. However, the equipment can be adapted to the demands of more technical material due to the technological advances.
If we replace the use of compressed air with gas mixes (argon/hydrogen) we will reduce the oxidisation of the cut and we will obtain clean and quality finishes. Thus, we will not need to carry out additional machining work before starting to weld. Furthermore, the use of gases in the cutting process will reduce the thermal contribution in the part, minimising deformations and permitting an increase in the cutting speed, thus increasing productivity.
Handling the gas plasma cutting equipment is no different to using compressed air equipment, so the worker’s production capacity will be immediate.
Discover the Gala Gar range of plasma cutting equipment here.
Moreover, if you wish to automate your plasma cutting equipment without making too high an investment, consult our CNC catalogue.
We park our cars more and more frequently in the streets, using our garage as a small workshop where we can work in either an amateur or semi-professional manner.
We have no problems with the normal hand tools (drill, grinding machine, etc.) We plug in the equipment and work no matter what the maximum consumption power is. However, welding appliances are something completely different.
Before deciding on incorporating a welding appliance into our workshop, we must bear in mind the available power, as the equipment may possibly consume more energy than what our network can supply and therefore we will not be able to weld. We will verify the power of the differential that we are going to connect the equipment to.
Once we know this detail, it is very simple to obtain the available power:
|Wall outlet amperage||Wall outlet consumption||Welding intensity|
|10 A||2200 W||70 A|
|15 A||3300 W||90 A|
|16 A||3500 W||100 A|
|20 A||4400 W||120 A|
|25 A||5500 W||150 A|
If we want everything to go smoothly, we must select an appliance that does not exceed the network consumption in adjusted welding intensity. In other words, in our example of a 16A differential, we could not weld at more than 100 amps, or in another words, a 2.5 mm rutile electrode.
Nowadays, however, we have much more efficient solutions that enable us to weld at greater intensity with less consumption. Gala 160 PFC enables us to weld up to an intensity of 150 amps in the same 16A differential. Here you can consult the features of this equipment.
The need to improve productivity and become increasingly competitive in the market is leading to the replacement of electrode welding with self-shielded tubular wire applications. This type of wire, commonly used in the United States, produces an increase in the welding speed and therefore a considerable reduction in production times.
Often the fear of the unknown or the tranquillity of familiarity with electrode welding prevents us from exploring other welding methods that could bring about greater benefits than the current ones.
What are the errors that prevent me from changing process?
1. Tubular wire does not have the same mechanical properties as electrode welding.
According to the requirements of the structural welding code and the bridge welding code of the AWS (American Welding Society), a self-shielded tubular wire satisfies the common requirements for structural applications. It is thus necessary to reassess the welding procedures.
2. Tubular wire welding is more difficult than electrode welding.
Quite the opposite, the position and movement of the torch is the same as in electrode welding, with the additional advantage that the wire does not change length from the torch, it being much smaller than the average length of an electrode, which makes it easier to control the arc and perform the welding in position.
We will maintain an adequate travel speed and gun angle to avoid slag inclusions. An indicator of success is the presence of an even line of slag after the bath.
3. The wire equipment is very large and prevents my mobility on site.
The technology available today permits the use of single-phase equipment that weighs less than 20 kilos. This equipment also has a protection system in the case of connection to generating sets, thus avoiding possible breakage due to voltage fluctuations. (Gala Invermig Syner 230 Mp).
4. With the current situation I cannot invest in new welding equipment.
Let me tell you about a personal experience: “A company engaged in manufacturing industrial buildings, spent 8 hours to fully weld each one of the structural pillars. This included base, consoles, structural reinforcements, tie-rods, etc. To carry out the work they also need cranes that support the structure and elevation platforms to take the welders up to their positions at height. When they decided to replace their electrode welding with tubular wire welding, their production times dropped to 2 hours per pillar, thus reducing their additional rental costs by 4. This is the type of saving that represents a direct profit; it is not a question of justifying the investment, but of getting a return on it as soon as possible.
1. Reduction of the number of splashes.
2. Less heat for applications on fine thicknesses and welding in position.
3. More even surface aspect and penetration
4. Less distortion of the base material.
5. Possibility of working with larger Ø wires in lower intensity ranges,
With these types of wire protection gas is not required during welding, therefore they are especially recommended for outdoor applications. At the same time, their high level of production with regards to welding by means of a coated metal electrode, reduce welding times and related costs (lease of platforms or cranes).
Normally cellulosic electrodes are used. They are adequate for welding in any position and they are mainly used to weld pipes vertically downwards because they produce very little rubble, they can be easily used and they achieve good penetration at the root pass in this position.
The protection system incorporated into the Gala G.E. line equipment becomes very important when the aim is to guarantee the life of the welding equipment:
- It prevents faults in erroneous connections to the 400 V network or supply networks with surge degrees of over 265 V.
- It prevents the frequent faults in connection to generating sets with non-stabilised voltage.
- It increases the life of the equipment in low quality supply lines where there are considerable voltage fluctuations with frequent under-voltage levels.
On the other hand, the Gala G.E. line equipment incorporates a highly reliable and robust halfbridge inverter topology, with top brand Mosfet power components, which guarantees an average life of more than 5000 hours.
It is a safety system that only reduces the equipment voltage during the arc striking phase, which is the MOST CRITICAL MOMENT TO SUFFER A POSSIBLE ELECTRICAL SHOCK.
So at that moment in the welding circuit, there are ZERO VOLTS and THE MAXIMUM AMPERES OF THE EQUIPMENT.
This electrical shock reduction system is recommended in risk situations and it is even compulsory in certain jobs and institutions.
• Welding in confined spaces, where the operator is in contact with the exposed live parts of a site. For example, outdoor Metal Structures, Interior of Pressurised Containers, Storage Tanks or Repairs in Naval Industry.
• Welding in damp atmospheres.
• Work at height, where a slight discharge, without consequences on the ground, may cause a loss of stability and falls with serious consequences.
• Welding in mining industry.
This safety system, therefore MODIFIES THE ELECTRODE IGNITION SYSTEM, as it reduces the initial no-load voltage required to establish the Electric Arc.
In such a way that the correct arc striking will be carried out by forcing the contact of the electrode with the plate, having 2 seconds to establish the arc and start the welding.
An electronic control system that reads the tension of the drops of the melted material, regulating the force of the arc to reduce or increase the size of the fusion and thus be able to maintain the electric arc constant and stable.
This prevents the electrode from sticking, preventing the drowning of the electrode, offering extra current to break the electric contact and maintain the ignition of the welding arc.
Due to the thermal expansion coefficient of aluminium, which is almost double than that of steel, when the wire heats at the contact point, the diameter increases in a higher proportion, therefore the diameter of the hole at the contact point must be bigger, with a slightly higher tolerance than for steel. This is why the use of special contact points for aluminium is recommended..
The equipment is not affected from the technical viewpoint, but the composition of the protection gas will directly affect the type of arc that our equipment generates.
We must remember that the electrical current established between the negative and positive poles of our equipment requires a conductive medium for it to circulate. Therefore, and depending on the nature of the gas used, each mixture will have different properties.
WHAT CHARACTERISTICS DEFINE A GAS MIXTURE?
Each gas has different characteristics that are made use of when combined with other gases:
Argon: It favours good arc stability.
Carbon dioxide: It improves penetration and increases the welding speed.
Helium: Compared with argon, it permits faster welding speeds.
Hydrogen: Its addition to the mixture increases energy intake, improves penetration and increases the welding speed.
Nitrogen: More recommended as a purge gas.
Oxygen: It improves the stability and fluidity of the welding bath.
NOTE: We must take into account that the increase of the percentage of a gas in the mixture reduces the proportion of the other gases to the same extent.
It is true that the use of one gas mixture or another is independent of the type of machine used. And that all welding equipment can work with all gas mixtures. But, in view of the influence of the gas on the arc generated by my welding equipment, it will be recommendable to use equipment that include different synergy programmes for different protection gases. Thus, it will increase the quality and control over our welding.
Gala Gar recommends using GPS 4000 (ref. 42300000), GPS 3000 (ref. 44100000) and GPS 2300 (ref. 53200000) to increase the welding possibilities.
And if you also want savings in your gas bill, see the following link.
The MIG welding is more productive than the MMA welding, where productivity losses are much more frequent. Apart from being more profitable, as for each kilo of electrode, around 35% is waste, whilst in solid wire and tubular wire only 5% is wasted.
El punto más crítico durante el soldeo del aluminio se encuentra a la salida de los rodillos, ya que a partir de ese punto el hilo se encuentra sometido a compresión, por lo que es fácil que se enrolle, se doble o se rompa.
Depending on the diameter and type of electrode, we will select the possible power sources and we will adjust the intensity of the equipment depending on the operating factor
|Type||I medium||Uo min|
|Rutile||(Ø elec. – 1) x 50||45-55V|
|Basic||(Ø elec. – 1) x 60||50-65V|
|Cellulosic||(Ø elec. – 1) x 70||60-75V|
|Aluminum||(Ø elec. – 1) x 80||45-55V|
|Special||(Ø elec. – 1) x 65||45-55V|
Its low deposition rate prevents it from being economical in materials with thicknesses over 8mm, recommending welding of root passes with this process and the rest of the procedure with another process which has a higher productivity.
Aluminium electrodes can be welded providing that your equipment has sufficient open-circuit voltage (U₀). You can check this detail on the equipment characteristics plate; if the value is over 70v you can weld aluminium electrodes.
The open-circuit voltage is what enables you to establish the arc; if there is not sufficient voltage, it will produce sparks, heat the part but it will not weld.
The use of Push-Pull torches is recommended. They include a pull system in the torch grips, which is synchronised with the machine itself. Like this a coordinated push and pull movement is carried out minimising the pull problems. Its use is indispensable for lengths over 6 meters.
This is one of the most common questions that our technical department receives. After choosing the torch that adapts to the intensity to be welded, and therefore to the sheet metal thickness, the type of torch must be selected:
- Manual valve: we will select this type when the machine has no operation connector
- With Euroconnector: when the machine has the same connection as the thread torch
- With pushbutton: in all other cases.
And remember that the consumables are just as important as the choice of torch because they will heat up more when the welding intensity is greater. Insofar as possible, we recommend using larger sized consumables with greater metrics, as these support the thermal increase better, increasing their duration.
Like the torches, the contact tips and other torch consumables will heat up more when the welding intensity is greater, as well as due to other criteria of influence mentioned in the torch.
The response to heating will be more violent in gas-cooled torches, as the thermal increase is greater and therefore the dilation of the consumables is greater.
Insofar as possible, we recommend using larger sized consumables with greater metrics, as these support the thermal increase better, increasing their duration.
Gala Gar offers these and many more spare parts for each one of the MIG torches.
1. The welding current intensity. The greater the intensity, the larger the torch model will be.
2. The protection gas used in welding. The lower the CO2 content in the mix, the lower its cooling power will be, and therefore, the torch should be bigger.
3. The type of arc used. The pulsed arc uses peak currents to release drops of nearly 400 amps, and the torch heats more than short-circuit welding. For this reason, we will select torches with greater thermal support.
4. The material welded upon. The thermal refractive power of the metal will be a fundamental factor and the melting temperature of the material will also have an influence on the heating the torch has to support.
|Base material||º Melting||Thermal REFRACTIVE POWER|
Therefore, we will use larger-sized torches when the thermal refractive power of the material is greater and when the melting temperature is higher.
5. We must also remember that the effect of heat is summative, therefore, the longer the bead, the greater the heating will be, and consequently, the higher the temperature the torch has to support.
Gala Gar also offers all the accessories for those torches. Discover them here, and if you have any queries, do not hesitate to contact us.
We must remember that the water cooling circuit exclusively affects the torch, so we can use an external system, such as the WCS 510 cooling module manufactured by Gala Gar, compatible with any welding equipment and replacing the torch (gas cooled) with another one (water cooled). As a general rule, we will place the cooling next to the power source and we must take 2 pipes from the cooling to the torch.
Este tipo de soldadura está especialmente indicada para equipos de oficinas, equipos de laboratorios, aparatos domésticos, moldeado de chapa, industria del automóvil, fabricación de herramientas, construcciones metálicas, etc.
Un calentamiento localizado y durante un periodo muy corto es una de las ventajas cruciales de la tecnología de soldadura de pernos. Por consiguiente los cambios en el material de la pieza a soldar se reducen al mínimo.
■ Para pernos de soldadura de M3 a M10 fabricados de acero, acero inoxidable, aluminio y latón
■ Recomendada para la soldadura de chapas de espesor fino con un grosor mínimo de 0,5 mm.
■ Sin procesos de taladrado, roscado, pegado, remachado o punzonado
■ Sin decoloración por la cara vista al soldar en chapas de espesor fino
■ Sin la debilitación de la pieza a soldar que normalmente se produce como consecuencia de la perforación o punzonado
■ Los puntos de la soldadura sólo tienen que ser accesibles por un lado
■ Uniones totalmente herméticas en tanto que no requieren la realización de agujeros.
■ Alta productividad como consecuencia de la corta duración de los ciclos de soldadura
■ Tecnología rentable de sujeción
■ No se necesita la protección del baño de fusión debido al ciclo de soldadura extremadamente corto de 1 - 3 ms.
■ Diseñados especialmente para aplicaciones en las que se requiera un acabado decorativo sobre paneles vistos.
■ Apenas alguna salpicadura de soldadura
Ver la gama de equipos de soldadura de pernos por condensadores