Weld Support Parts Blog

  • Alumina Oxide vs. Ceramic Flap Discs: Which Is Right for Your Application?

    When it comes to abrasive flap discs, selecting the proper material can significantly influence the efficiency, lifespan, and quality of your grinding and finishing applications. Two of the most common abrasive flap disc materials you’ll encounter are alumina oxide and ceramic. In this post, we’ll compare these two options and help you decide which type will best suit your needs.

    Alumina Oxide Flap Discs: Reliable and Cost-Effective

    Advantages:

    • Cost-Effective: Alumina oxide flap discs are generally more affordable, making them an excellent choice for general-purpose grinding, deburring, and finishing tasks.
    • Versatile: Suitable for use on a variety of metals, including mild steel, aluminum, and other non-ferrous metals.
    • Availability: Widely available across most hardware stores or industrial suppliers.

    Drawbacks:

    • Shorter Life Span: Alumina oxide discs tend to wear out quicker, especially when used on tough metals or demanding applications.
    • Lower Heat Resistance: These discs generate more heat during grinding activities, potentially leading to discoloration or warping of sensitive metals.
    4-1/2″ x 7/8″ 40 Grit[See Price on Amazon]
    4-1/2″ x 7/8″ 60 Grit[See Price on Amazon]
    4-1/2″ x 7/8″ 80 Grit[See Price on Amazon]
    4-1/2″ x 7/8″ 120 Grit[See Price on Amazon]

    Ceramic Flap Discs: Heavy-Duty Performance and Longer Life

    Advantages:

    • Longer Lasting: Ceramic abrasives are engineered to be highly durable, significantly outlasting alumina oxide discs in heavy-duty applications.
    • Cooler Operation: Ceramic flap discs generate less heat during use, making them ideal for working with stainless steel, titanium, or other heat-sensitive alloys.
    • Aggressive Grinding Action: Ceramic discs maintain a sharp edge longer, providing faster and more consistent material removal rates.

    Drawbacks:

    • Higher Initial Cost: Ceramic flap discs do come with a higher upfront price tag, although their longer lifespan and efficiency may offset the initial expense.
    • Not Always Necessary: For lighter jobs or infrequent use, ceramic discs may be considered overkill and not cost-effective.

    Making the Right Choice:

    The decision between alumina oxide and ceramic flap discs largely depends on your specific application and priorities:

    • Choose Alumina Oxide if: You’re performing general-purpose tasks, working on softer metals, or looking for a budget-friendly abrasive option for occasional use.
    • Choose Ceramic if: You’re frequently grinding or finishing harder metals, require faster material removal, want to reduce downtime for disc changes, or need to minimize heat-related issues.
    4-1/2″ x 7/8″ 40 Grit[See Price on Amazon]
    4-1/2″ x 7/8″ 60 Grit[See Price on Amazon]
    4-1/2″ x 7/8″ 80 Grit[See Price on Amazon]

    Final Thoughts:

    Both alumina oxide and ceramic flap discs have their place in your workshop. Alumina oxide discs offer versatility and affordability, making them suitable for general tasks, while ceramic flap discs provide superior performance, durability, and efficiency for more demanding applications. By carefully evaluating your needs, budget, and types of metal you’re working with, you can confidently select the best abrasive solution for your project.

    ** Note: ** I may earn a comission on any purchased made through Amazon from the links above.

  • Comparing 7018 and 6011 Welding Rods: Understanding Their Unique Strengths and Applications

    Welding is an essential process used in various industries, from automotive to construction. The choice of welding rods can significantly impact the quality and strength of the welds produced. Among the myriad options available, two popular welding rods are the E7018 and E6011. Each serves specific purposes and shines in various applications. In this blog post, we’ll explore the differences between these two welding rods, their characteristics, and where each excels.

    Understanding the Basics

    E7018 and E6011 are designations from the American Welding Society (AWS) that categorize the rods based on their composition and usability.

    E7018 Welding Rods

    • Composition: E7018 rods are low-hydrogen, iron powder rods typically made up of mild steel with manganese and iron oxide. The ‘E’ stands for electrode, while ’70’ indicates that the rod can produce welds with a minimum tensile strength of 70,000 psi. The ‘1’ denotes that the rod can be used in all positions, and the ‘8’ signifies that it is a low-hydrogen type.
    • Coating: These rods have a thick coating, which helps to produce a smooth weld with minimal impurities. This coating enables them to maintain a stable arc and control the hydrogen levels in the weld, reducing cracking.
    • Weld Characteristics: E7018 rods produce a strong, ductile weld with excellent impact resistance and crack resistance. They are ideal for structural applications where strength and integrity are paramount.

    E6011 Welding Rods

    • Composition: E6011 rods are also mild steel rods but feature a different composition that includes cellulose. Much like E7018, the ‘E’ indicates electrode, ’60’ signifies a minimum tensile strength of 60,000 psi, ‘1’ allows for all-position welding, and ‘1’ indicates that it is suitable for use with alternating current (AC) as well as direct current (DC).
    • Coating: With a thinner coating, E6011 rods are designed to create a more fluid weld pool, which is advantageous for working on contaminated surfaces.
    • Weld Characteristics: The E6011 produces a fast-freezing weld that can penetrate deep, making it suitable for thicker materials or when working in less-than-ideal conditions. However, the weld may have a rougher appearance and less tensile strength compared to E7018 welds.

    Key Differences

    1. Tensile Strength and Ductility

    • E7018: High tensile strength (70,000 psi) and a more ductile weld, making it suitable for structural welds that require high integrity.
    • E6011: Slightly lower tensile strength (60,000 psi) but sufficient for many applications. Suitable for thicker materials.

    2. Hydrogen Control

    • E7018: Low-hydrogen exposure minimizes the risk of cracking, ideal for high-stress applications like pressure vessels or structural supports.
    • E6011: Higher hydrogen content may lead to cracking in sensitive applications, though it performs well on dirty or rusted surfaces.

    3. Weldability

    • E7018: Requires specific preheating and post-weld heat treatment. Best suited for clean conditions.
    • E6011: Can weld through rust and contaminants, making it versatile for fieldwork and maintenance tasks.

    4. Weld Appearance and Cleanup

    • E7018: Produces smooth, aesthetically pleasing welds with minimal clean-up required.
    • E6011: Generally leaves a rougher bead that can require more clean-up due to slag.

    Applications

    • E7018: Commonly used in structural steel applications, pressure vessels, shipbuilding, and any situation requiring high strength and reliability. It is frequently employed in construction and fabrication of bridges, buildings, and heavy equipment.
    • E6011: Ideal for maintenance, repair, and farm equipment work, as well as for welding thin materials or in tight spaces. Its ability to work in less-than-ideal conditions makes it a favorite among welders in the agricultural and manufacturing sectors.

    Conclusion

    Choosing between E7018 and E6011 welding rods depends on the specific requirements of the project you’re undertaking. If you need high-strength, crack-resistant welds with a smooth finish for structural applications, E7018 is the clear choice. On the other hand, if you’re tackling maintenance jobs, working with thicker metals, or need to deal with contaminants, E6011 will serve you well.

    Understanding the characteristics, strengths, and ideal applications of these rods ensures that you make informed decisions in your welding projects, contributing to the quality and longevity of your work. Happy welding!

  • Setting Up a MIG Welder with Gas for Welding Mild Steel: A Step-by-Step Guide

    MIG welding, also known as Gas Metal Arc Welding (GMAW), is a popular choice among hobbyists and professionals alike for its versatility and efficiency. When it comes to welding mild steel, using a MIG welder with gas provides several benefits, including cleaner welds and better penetration. In this guide, we’ll take you through the steps of setting up your MIG welder with gas for welding mild steel.

    Step 1: Gather Your Materials and Tools

    Before you start setting up your welder, you’ll need to gather all the necessary materials and tools. Here’s what you’ll need:

    – MIG welder

    – Welding gas (usually a mixture of Argon and CO2)

    – MIG welding wire (ER70S-6 for mild steel)

    – Gas regulator and flowmeter

    – Ground clamp

    – Welding helmet and safety gear

    – Wire brush or grinder for metal preparation

    – Protective gloves and clothing

    Step 2: Prepare Your Workspace

    Safety first! Make sure your welding area is clean, well-ventilated, and free from any flammable materials. Wear appropriate safety gear, such as a welding helmet, gloves, and fire-resistant clothing.

    Step 3: Set Up the Gas Cylinder

    1. **Position the Cylinder**: Place the gas cylinder upright in a secure location where it won’t get knocked over. Ensure it’s away from direct sunlight or heat sources.

    2. **Install the Regulator**: Remove the protective cap from the gas cylinder. Align the regulator with the cylinder’s valve and screw it into place. Make sure it’s tightly secured.

    3. **Check for Leaks**: After connecting the regulator, use soapy water on the connection points to check for leaks. If bubbles form, re-tighten the connection.

    Step 4: Connect the Welding Gun

    1. **Feed the Wire**: Take your spool of MIG welding wire (ER70S-6 for mild steel) and place it on the spool holder. Feed the wire through the drive rolls of the welder. Make sure to set the drive rolls for the correct size of wire.

    2. **Attach the Gun**: Connect the welding gun to the welder as per the manufacturer’s instructions. Ensure that the wire is properly threaded through the gun.

    Step 5: Set the Gas Flow Rate

    1. **Adjust the Flowmeter**: With the gas cylinder open, check the flow rate on the flowmeter. Typically, a flow rate of 15-25 cubic feet per hour (CFH) is suitable for MIG welding mild steel. Adjust the flow rate to where it is required.

    2. **Check for Proper Gas Coverage**: It’s essential to have the right gas coverage to protect the weld pool. A steady flow of gas will create a protective shield around the weld.

    3. **Double Check the Cylinder When Finished**: It’s very important to turn off your gas bottle after you’re done welding. If you leave it open, you may lose all of your gas

    Step 6: Set the Welder Parameters

    1. **Voltage and Amperage**: Refer to the welder’s manual for the recommended voltage and amperage settings for the thickness of the mild steel you are working with. For example, for 1/8 inch (3.2 mm) steel, you might use around 18-19 volts and 120-150 amps.

    2. **Polarity**: Ensure that your welder is set to the correct polarity for MIG welding, which is DCEN (Direct Current Electrode Negative).

    Step 7: Ground the Workpiece

    A good ground is crucial for successful welding. Connect the ground clamp to your workpiece or to a clean, bare metal surface nearby. Ensure a firm connection to avoid fluctuations during welding.

    Step 8: Prepare the Metal Surface

    Before you start welding, clean the surface of the mild steel using a wire brush or grinder. Remove any rust, paint, or contaminants to ensure a strong weld. The cleaner the metal, the better the weld quality.

    Step 9: Safety Checks

    Before you start welding, verify that:

    – You’re wearing all necessary safety gear.

    – The area is properly ventilated.

    – There are no flammable materials nearby.

    Step 10: Start Welding

    1. **Test Weld**: It’s a good idea to do a test weld on a scrap piece of mild steel. This can help you adjust your settings if needed.

    2. **Weld With Controlled Motion**: Hold the welding gun at a comfortable angle and move at a steady pace along the joint. Start with a slight weave motion if necessary, applying consistent pressure.

    3. **Watch the Weld Pool**: Keep an eye on the weld pool; it should melt and flow smoothly. Adjust your travel speed if you notice excessive spatter or lack of penetration.

    Step 11: Inspect the Weld

    Once you’ve completed the weld, inspect it for consistency and strength. Look for even bead appearance and ensure there are no gaps or inclusions.

    Conclusion

    Setting up a MIG welder with gas for welding mild steel is a straightforward process if you follow these steps. From gathering your materials to conducting safety checks and initiating your weld, each step is crucial for achieving high-quality welds. Take your time to ensure everything is set up correctly, and don’t hesitate to practice on scrap metal to hone your skills. With patience and practice, you’ll become proficient at MIG welding in no time! 

    Happy welding!

    For further assistance, feel free to reach out or leave any questions or comments below!

  • Best Welding Helmet Under $120

    Finding the right welding helmet can be a daunting task, especially when you’re on a budget. With so many options available, how do you know which one offers the best protection and features without breaking the bank? As someone who has spent 18 years in the welding supply industry, I understand the importance of a reliable welding helmet that won’t compromise your safety or comfort. In this post, I’ll highlight some of the best welding helmets under $100, ensuring you can find a great product that meets your needs and keeps you protected while welding.

    Comparison Table

     

    Helmet Model Price Rating Key Features
    Arc One Carrera $109.50 4.5/5 Auto-darkening, lightweight, 2 sensors
    Hobart 770890 $89.99 4.3/5 Adjustable shade, comfortable fit

    YES LYG-Q800D

    		 $89.98 4.6/5 High-quality optics, great visibility
    Antra AH6-260-0000 $59.99 4.4/5 Large viewing area, solar-powered

     

    Table made on 5-22-25

    1. Arc One Carrera

    The Arc One Carrera is a dependable choice for welders seeking a balance of performance and affordability. Its auto-darkening feature allows for seamless transitions between welding and non-welding tasks.

    **Pros:**

    – Auto-darkening lens

    – Lightweight design

    – Two sensors

    **Cons:**

    – Limited shade adjustment options

    – May not fit all head sizes comfortably

    **Why It’s a Good Choice:** This helmet is ideal for both beginners and experienced welders looking for a quality helmet without a hefty price tag. 

    [Check Price on Amazon]

    2. Hobart Creator 770870

    The Hobart 770870 helmet is designed for comfort and usability, making it suitable for extended welding sessions. Its adjustable shade range helps you adapt to various welding environments.

    **Pros:**

    – Adjustable shade settings

    – Comfortable fit with padded headgear

    – Good visibility

    **Cons:**

    – Heavier than some competitors

    – Can fog up in humid conditions

    **Why It’s a Good Choice:** The Hobart 770870 is perfect for those who value comfort and versatility at an affordable price.

    [Check Price on Amazon]

    3. Yeswelder LYG-Q800D

    The Yeswelder LYG-Q800D is known for its superior optical quality and performance. Its high-quality optics provide excellent visibility, ensuring that you can see your work clearly.

    **Pros:**

    – Exceptional optical clarity

    – Lightweight and well-balanced

    – Durable construction

    **Cons:**

    – Limited auto-darkening features

    – Pricier than some basic models

    **Why It’s a Good Choice:** If you’re looking for a helmet that offers both comfort and clarity, the YESWELDER LYG-Q800D is a fantastic option within this budget.

    [Check Price on Amazon]

    4. Antra AH6-260-0000

    The Antra AH6-260-0000 is a budget-friendly helmet that offers a large viewing area and solar-powered functionality, making it a great choice for hobbyists and professionals alike.

    **Pros:**

    – Large viewing area

    – Solar-powered with battery backup

    – Lightweight and comfortable

    **Cons:**

    – Basic design

    – Limited features compared to higher-end models

    **Why It’s a Good Choice:** This helmet is an excellent option for those just starting out in welding, offering great value and essential features without stretching your budget.

    [Check Price on Amazon]

    In summary, if you’re looking for the best welding helmet under $120, the **Arc One Carrera** stands out as the top pick. It combines essential features like auto-darkening with a lightweight design, making it suitable for both beginners and experienced welders. With its excellent balance of quality and affordability, you can feel confident in your choice, ensuring you stay safe while welding. Happy welding!

  • Comparing 2×4 Auto Darkening Lenses from Miller Electric, Lincoln Electric, and Arc One Singles

    Welding is a demanding task that requires not only skill and precision but also the right protective gear. Among the essential tools for any welder is the auto-darkening lens. This technology allows welders to see their work clearly before striking an arc and then darkens automatically to protect the eyes during welding. In this post, we’ll provide an in-depth comparison of 2×4 auto darkening lenses from three industry-leading brands: Miller Electric, Lincoln Electric, and Arc One Singles. We’ll explore their features, benefits, and user testimonials to help you make an informed decision.

    1. Miller Electric 2×4 Auto Darkening Lens

    Overview:

    Miller Electric is a trusted name in the welding industry, known for its high-quality equipment and innovative technology. Their 2×4 auto darkening lens is designed for professional welders who demand clarity and performance.

    Features:

    – **Fast Response Time:** The lens boasts a quick switching speed, darkening in milliseconds when an arc is struck, ensuring optimal eye protection.

    – **Fixed Shade Range:** Welders can select from the lens shades 8-11 to accommodate various welding processes, including MIG, TIG, and stick welding.

    – **True Color Technology:** This feature enhances visibility by providing a more natural color spectrum, allowing welders to see their work with greater detail.

    **User Testimonials:**

    – “The Miller lens offers fantastic clarity and the auto-darkening feature is incredibly responsive. I’ve used it in various conditions, and it never fails to protect my eyes.”

    – “I love the adjustable shade settings; it makes my welding experience much better, especially when switching between different materials.”

    **Most Common Shade 10 – Purchase Link:**

    [Buy Miller Electric Lens on Amazon]

    —

    2. Lincoln Electric 2×4 Auto Darkening Lens

    Overview:

    Lincoln Electric is another heavyweight in the welding industry, recognized for its durable and reliable welding equipment. Their auto darkening lens is no exception, offering a blend of performance and comfort.

    Features:

    – **Large Viewing Area:** The Lincoln lens features a wide viewing area, allowing for better visibility of the workpiece and surroundings.

    – **Superior UV/IR Protection:** This lens provides excellent protection against harmful UV and infrared rays, essential for long-term eye safety.

    – **Multiple Sensitivity Settings:** Welders can adjust the sensitivity of the lens to ensure it responds appropriately to the light generated by different welding processes.

    User Testimonials:

    – “Lincoln Electric lenses are my go-to. They provide excellent protection and visibility, and I love the large viewing area while working.”

    – “I appreciate how easily adjustable the settings are. The sensitivity options are perfect for my varied welding projects.”

    **Purchase Link:**

    Buy Lincoln Electric Lens on Amazon

    —

    3. Arc One Singles 2×4 Auto Darkening Lens

    Overview:

    Arc One is known for its innovative approach to welding safety gear, and their Singles auto darkening lens is lightweight yet robust, making it popular among both hobbyists and professionals.

    Features:

    – **Lightweight Design:** This lens is incredibly light, reducing neck strain during extended welding sessions.

    – **Quick Adjustment Time:** Arc One’s technology allows for rapid adjustment to changing light conditions, ensuring optimal protection and visibility at all times.

    – **Enhanced Battery Life:** The lens features a long-lasting battery that minimizes the need for frequent changes, allowing welders to focus on their work.

    **User Testimonials:**

    – “Arc One Singles are lightweight and comfortable, perfect for long hours of welding. I hardly notice I’m wearing it!”

    – “I was impressed by the battery life and how quickly it adjusts to different lighting. It’s a game-changer for my projects.”

    **Purchase Link:**

    Buy Arc One Singles Lens on Amazon

    “`html

    Feature Miller Electric Lincoln Electric Arc One Singles
    Fast Response Time Yes Yes Yes
    Adjustable Shade Range not adjustable 9 to 13 6 to 13
    Viewing Area Standard Standard Standard
    UV/IR Protection Yes Yes Yes
    Weight Moderate Moderate Lightweight
    Battery Life Standard Standard Enhanced
    Price Range $$$ $$ $

    “`

    Choosing the right auto-darkening lens can significantly improve your welding experience. Each of the brands we’ve compared—Miller Electric, Lincoln Electric, and Arc One Singles—offers unique benefits that cater to different preferences and needs. Whether you prioritize clarity, weight, or battery life, there’s a lens that will suit you perfectly. 

    Make sure to evaluate your specific welding tasks and environment to select the best lens for your situation. 

    **Note:** I may earn a commission for any purchases made on Amazon through the links above.

  • The Top Welding Helmets of 2025: Protect Your Eyes and Enhance Your Skills

    The Top Welding Helmets of 2025: Protect Your Eyes and Enhance Your Skills

    Welding is a demanding profession that requires not only skill and precision but also the right safety gear. One of the most critical pieces of equipment for any welder is a high-quality welding helmet. As we step into 2025, advancements in technology have led to the release of some outstanding welding helmets that offer enhanced protection, comfort, and features. Below, we’ve compiled a list of the top welding helmets of 2025 to help you make an informed choice for your welding needs.

    1. Lincoln Electric Viking 3350

    The Lincoln Electric Viking 3350 is renowned for its superior optics and comfort. With a 1/1/1/1 optical clarity rating, this helmet provides excellent visibility during welding. The True Color technology ensures that you see the weld puddle in its true colors, making it easier to work with. It features a large viewing area and is lightweight, making it comfortable for extended use.

    Purchase on Amazon: Lincoln Electric Viking 3350

    Replacement Parts: If you need parts for the Viking 3350, check out our parts breakdown here.

    2. 3M Speedglas 9100

    The 3M Speedglas 9100 is an industry favorite due to its comfort and advanced features. This helmet boasts a unique auto-darkening filter that adjusts to varying light conditions. The helmet is designed to reduce neck strain with its balanced weight distribution, making it ideal for professional welders.

    Purchase on Amazon: 3M Speedglas 9100

    3. Hobart Impact Auto-Darkening Welding Helmet

    The Hobart Impact helmet offers excellent value for money. It features a lightweight design and an adjustable headgear for maximum comfort. With a viewing area of 8 square inches, this helmet provides a clear view of your work area. The auto-darkening feature activates within 1/25,000 of a second, ensuring your eyes are protected instantly.

    Purchase on Amazon: Hobart Impact Welding Helmet

    Replacement Parts: Need parts for the Hobart Impact? Check our parts breakdown here.

    4. ESAB Sentinel A50

    The ESAB Sentinel A50 is a cutting-edge helmet that combines style with functionality. It features a high-definition digital display and a wide viewing area. The helmet is equipped with adjustable sensitivity and delay settings, allowing you to customize it to your specific welding conditions. Its sleek design and comfortable fit make it a popular choice among welders.

    Purchase on Amazon: ESAB Sentinel A50

    Replacement Parts: For parts related to the Sentinel A50, find our breakdown here.

    5. Miller Digital Infinity Welding Helmet

    The Miller Digital Infinity helmet is known for its innovative design and advanced technology. With a large viewing area and a 1/1/1/1 optical clarity rating, this helmet allows for excellent visibility. The auto-darkening lens has multiple settings to accommodate various welding processes, making it versatile for all types of welders.

    Purchase on Amazon: Miller Digital Infinity

    Replacement Parts: Check out our parts breakdown for the Miller Digital Infinity here.

    Conclusion

    Investing in a high-quality welding helmet is essential for any welder, whether you’re a beginner or a seasoned professional. The helmets listed above are among the best options available in 2025, offering various features to enhance your welding experience while keeping you safe.

    Don’t forget to check out our website, Weld Support Parts, for any replacement parts you may need for these helmets. Stay safe and happy welding!

    Disclosure: This post contains affiliate links. We may earn a small commission at no cost to you.

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