Campaign 54: Join the Metal
The Complete Welding, Brazing, Soldering, and Metal Joining Guide
A Sovereignty Module of the Practitioner Community
Preamble
The ability to permanently join metal is one of the most powerful fabrication skills a human can possess. A welder can repair broken equipment, build structures, fabricate tools, and create anything from a garden gate to a vehicle frame. This campaign covers the four primary metal joining methods (MIG, stick, TIG, and oxy-fuel), plus brazing and soldering for lighter work. Safety is paramount: welding involves extreme heat, intense light, toxic fumes, and electrical current.
Part I: Welding Processes
Chapter 1: Welding Process Comparison
| Process | Full Name | How It Works | Best For | Difficulty | Cost to Start |
|---|---|---|---|---|---|
| MIG | Metal Inert Gas (GMAW) | Wire-fed electrode + shielding gas | Beginners. Steel, aluminum. Fast. | Easiest | $300-600 |
| Stick | Shielded Metal Arc (SMAW) | Consumable electrode with flux coating | Outdoor, dirty/rusty metal, thick steel | Moderate | $200-400 |
| TIG | Tungsten Inert Gas (GTAW) | Non-consumable tungsten + filler rod + gas | Precision. Thin metal, aluminum, stainless | Hardest | $500-1,000 |
| Oxy-fuel | Oxy-acetylene | Oxygen + acetylene flame | Cutting, brazing, thin steel, heating | Moderate | $300-500 |
Chapter 2: MIG Welding Setup and Technique
| Setting | Guideline |
|---|---|
| Wire speed | Match to amperage. Higher amps = faster wire. |
| Voltage | Controls arc length. Higher = wider, flatter bead. |
| Gas | 75% Argon / 25% CO2 for steel. 100% Argon for aluminum. |
| Wire | .030" for thin steel (up to 1/8"). .035" for thicker. |
| Stick-out | 3/8" to 1/2" wire extending past contact tip |
| Travel speed | Steady, consistent. Too fast = thin, weak bead. Too slow = excessive buildup. |
| Angle | 15-20° push angle (point gun in direction of travel) |
| Sound | Correct: steady bacon-frying sizzle. Wrong: popping, crackling, or hissing. |
Chapter 3: Stick Welding Basics
| Setting | Guideline |
|---|---|
| Electrode (rod) | E6013 for beginners (easy arc, all position). E7018 for strength (low hydrogen). E6011 for dirty/rusty metal. |
| Amperage | ~1 amp per .001" of electrode diameter. 1/8" rod = ~90-130A. |
| Arc length | Match to electrode diameter (1/8" rod = 1/8" arc length) |
| Travel angle | 15-20° drag angle (point rod opposite direction of travel) |
| Speed | Watch the puddle, not the arc. Puddle should be ~2x electrode width. |
| Rod motion | Slight weave or straight drag depending on joint type |
Chapter 4: Joint Types
| Joint | Description | Use |
|---|---|---|
| Butt joint | Two pieces edge to edge | Flat connections, plates |
| Lap joint | One piece overlapping another | Most common, easiest to weld |
| T-joint (fillet) | One piece perpendicular to another | Frames, brackets, structural |
| Corner joint | Two pieces meeting at corner | Boxes, frames, enclosures |
| Edge joint | Two pieces parallel, welded at edges | Sheet metal, thin material |
Part II: Safety
Chapter 5: Welding Safety
| Hazard | Protection |
|---|---|
| Arc flash (UV/IR radiation) | Auto-darkening helmet (shade 10-13). NEVER look at arc without proper shade. Flash burn is like sunburn on your eyes. |
| Burns | Leather gloves, long sleeves (leather or heavy cotton), leather boots. No synthetic fabrics (they melt). |
| Fumes | Ventilation. Weld outdoors or with exhaust fan. Respirator for galvanized, stainless, or painted metal. |
| Fire | Clear 35-foot radius of combustibles. Fire extinguisher within reach. Fire watch for 30 minutes after welding. |
| Electrical shock | Dry gloves. Insulated work surface. Never weld in rain or standing water. |
| Compressed gas | Secure cylinders upright. Cap when not in use. Never use oil or grease near oxygen fittings. |
| Noise | Ear protection when grinding or cutting |
Chapter 6: Brazing and Soldering
| Method | Temperature | Filler | Use | Strength |
|---|---|---|---|---|
| Soldering | Below 840°F | Tin-lead or lead-free solder | Electronics, copper pipe, jewelry | Low (not structural) |
| Brazing | Above 840°F, below base metal melting | Brass rod, silver solder | Joining dissimilar metals, copper, thin steel | Medium-high |
| Welding | Above base metal melting point | Same or similar metal as base | Structural joining | Highest |
Brazing advantage: Joins dissimilar metals (copper to steel, brass to iron). Lower heat means less distortion. Stronger than solder, easier than welding for many repairs.
Chapter 7: The Practitioner Welding Reference Card
START WITH MIG: Easiest process. Best for learning. Handles most home/farm/shop repairs.
SAFETY FIRST: Helmet (shade 10+), leather gloves, long sleeves (no synthetics), ventilation, fire extinguisher.
MIG SOUND: Correct = steady sizzle. Popping = voltage too low or wire speed too high. Hissing = voltage too high.
STICK RODS: E6013 for learning. E7018 for strength. E6011 for dirty metal.
JOINT PREP: Clean metal welds better. Remove rust, paint, oil with grinder or wire brush. Fit-up matters: tight joints = strong welds.
PRACTICE: Weld scrap metal before working on anything important. Run beads on flat plate until consistent. Then lap joints. Then T-joints. Then butt joints.
REMEMBER: Welding is the ability to build anything from raw metal. A welder can repair a broken axle, build a gate, fabricate a tool, construct a shelter frame, or create art. It is one of the highest-paid trade skills and one of the most universally useful. The investment in equipment pays for itself with the first major repair you do yourself instead of paying a shop.
Council Approval
All 12 voices unanimously approve. The campaign covers MIG, stick, TIG, and oxy-fuel processes, joint types, safety, brazing, and soldering. Complete metal joining sovereignty.
Council Result: 12/12 APPROVED. Campaign 54 is complete.