As complex as it is, welding is actually made up of a simple task that is repeated throughout the fabrication process of a metal body. This task refers to the making of joints. There are all kinds of welding joints with the most common type being a butt joint. This type of welding joint is made with the two workpieces that need to be joined being on the same plane.
The pieces do not overlap and are nearly parallel which makes it easy to weld them together. A butt weld joint is quite simple and it also comes in different variations. These include single bevel, double bevel, square, single J, double J, single and double V, and single and double U. But in order to make any of these butt joints, you'll need panel welding clamps.
Panel Clamps
What Are They?
If you're going to be welding sheet metal with butt joints you should rely on butt welding clamps. These clamps are made up of a wing nut, block, and a toggle bar that help keep large sheets of metal in place. Quality panel clamps are able to work together with locking clamps to provide more stability and help you make a quality butt joint.
Benefits
Alongside keeping sheet metal in place, panel clamps also help you make clean welds. You can also use panel welding clamps for fabrication projects and for the assembly of large structures too. As long as you know how to use panel welding clamps you'll be able to make butt joints just like an experienced welder.
How To Use Them
1. To make good use of butt welding clamps you need to first loosen the wing nut to the point where there is enough space for the sheet metal to slide in. The sheet metal is positioned between the block and the toggle bar.
2. Once the sheet is in place you can then tighten the wing nut to secure the metal piece. Keep in mind that one panel clamp won't be enough. You'll have to employ multiple of them in order to stop the entire workpiece from moving.
How to Make a Butt Weld Joint
Preparation
1. Before you start collecting all your gear and equipment and start welding workpieces together you should first clean the workpieces you want to weld. Dirt, grease, dust and anything that can compromise the weld should be removed.
2. This is why you should use a lint-free cloth soaked in the correct cleaning solution. This could be ethyl alcohol, chlorothene, isopropyl alcohol, or trichloroethane. Once you've cleaned the workpieces you should then clamp the meeting ends together. Do this properly so that the axial misalignment isn't more than 10% of the thickness of the metal sheets.
3. Right before you start welding you should plane the edges of both workpieces so you get a clean and proper weld. You should not touch the workpieces once they're planed as this can lead to contamination. Make sure they are positioned correctly before you plane them so you start making the joint right away.
Weld
1. When it comes to making the actual butt weld joint you should get straight into it. If using a TIG welder apply several tack welds so that the metal is in position and then join the two pieces by completing the bead with additional tacks. You can also push a metal pool along the entire length of the joint. Once the weld is made and has cooled, sand it down.
2. If you're using an MIG welder, you should start out the same way by making several tack welds along the joint. When you've made a couple of them you should cool the area of the welds with compressed air. Don't go too close though as it can make the hot weld porous. After welding the two metal pieces together you should then grind down the weld so it appears more seamless.
Check
1. When you've made the weld and grinded/ sanded it down you should then inspect it. Check if the weld has a uniform bead around its entire length. Check if the centre notch of the bead is above the diameter outside of the two welded workpieces.
2. Are there any signs of break up on the surface or are there any signs of contamination? Check if the bead has a reflective finish, which is a sign of overheating. You should also inspect for any misalignment of the welded parts which again shouldn't be greater than 10% of their thickness.
Defects
1. Like anything in life, when welding you should expect any mishaps which can result in defects. Your weld bead can have its centre notch too deep which means the pressure or temperature was too low.
2. The weld bead can also look like it's shrunken. This can be due to the temperature, pressure, and time parameters not being adjusted properly. Also, the weld bead could be porous which can be the case if the humidity in your work area is too high.
