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Posts tagged: welding wire

Top 3 Safety Tips for Welding Wire and Other Materials

Anyone familiar with welding knows that welding accidents aren’t pretty and should be avoided at all costs. As the practice of using heat and flux to fuse together two pieces of metal, welding is a dangerous activity, even for seasoned pros. MIG welding in particular is susceptible to accidental injuries and damage around the workplace. But how can you prevent accidents from happening? That is what we’ll be discussing in this article.

  • Protect Yourself

Welding produces sparks and high intensities of both light and heat. One of the first lessons that every welder learns is that they should wear a full face mask when using an arc welder in order to prevent the corneas of their eyes from getting damaged.

With MIG welding, however, there is an additional danger to the welder that needs to be addressed. MIG welding produces light that contains strong UV rays. These rays can burn and blister the skin unless the welder wears gloves and covers as much of their body as possible with clothing. This precaution also helps prevent burns from flying molten metals that are produced during welding wire together.

  • Protect Your Work Area

It’s important to fireproof an area as much as possible when MIG welding. Keeping the area free of plastic, paper, sawdust, and other highly flammable workshop materials is essential to the safety of all workers and welders that are using the space. Additionally, keeping a fire extinguisher nearby is always a smart move while welding.

  • Protect Others

When it comes to MIG welding, it’s important to focus on the safety of everyone involved. Welding wire gives off ozone and some alloys can even release fumes that lead to severe metal poisoning. Whether you’re working alone or with others, it’s essential to have a well-ventilated space in order to work.

Even though these tips might seem fairly obvious, it’s easy to overlook simple things because of impatience. Always make sure that someone who is familiar with the process is there and that the project is thoroughly planned out before welding in order to avoid common safety hazards.

 

Information About Foil Tape And Tinned Copper Shielding

Copper is commonly used for shielding purposes, usually as a foil tape or tinned copper shielding. Information about foil tape and tinned copper shielding is readily available online. Both foil tape and tinned copper shielding are used to shield cables, eliminate EMI/RFI interference, thermal and electrical purposes and others.

Foil tapes are available in two kinds: aluminum and copper. Both are conductive acrylic adhesive. Foil tapes are used for purposes that require reliable point-to-point contact like EMI/RFI shielding, static charge draining and grounding. These foil tapes have many uses in electronic design, prototyping for test laboratories and for design and troubleshooting purposes. Copper foil tapes in particular is a cost effective to shield against EMI/RFI interferences. It is very easy to apply and therefore, time saving. Copper foil tapes are conductive all throughout including the adhesive which makes it ideal for cable shielding, shielding electrical connections between surfaces of sheets and foils, die-cuts, temporary shielding during tests and as an antistatic.

Tinned copper shield is available in mesh and flat braid. Tinned copper shielding (flat braid) is rolled flat and braid at the time of manufacture. It is very flexible which makes it a great protective braid over hoses and tubings. It is also useful for shielding around cables, ground straps, battery grounding, and as bonding strap for vehicles, aircraft and marine equipment. It also eliminates ignition interference and can be used for any application that needs woven, tinned copper braid. Tinned copper shield has minimum shield coverage of 95%. Specifications QQ-W-343 type S and ASTM B-33 are met for woven tinned copper shields.

More information about foil tape and tinned copper shielding including the thickness, approximate awg, ampacity and others differ depending on the type of tinned copper shielding to be used as well as the shielding capacity of foil tapes which also differ with its size. Copper Foil tapes are available in typical industry standard metric cut sizes, example, 24mm for every 1 inch of nominal tape width ordered. Note that rolls are 5% narrower than the nominal size. In this case, the product’s actual size is 25.4mm wide.

The conductive adhesive of copper foil tapes is ideal for modifications of printed circuit boards, repairs of security alarm circuits and for layout and design of wiring board prototypes. It is very ideal for wrapping cables to shield EMI/RFI and to provide electrical continuity by seaming of EMI/RFI shielded rooms. It is also used for draining of static charge and surface contact to materials such as plastic or aluminum which is non-solderable. Its copper-bright color is non-tarnishing and annealed making it also great for arts and decorative projects.

For better shield coverage, tinned copper shield is recommended. Its woven, tinned copper construction provides a minimum coverage of 95%. It has a nominal thickness of .020” making it very flexible and ideal for use as bonding strap for marine equipment, aircraft and vehicles.

You can find other specific information about foil tape and tinned copper shielding at the manufacturer’s website or you may give them a call for more assistance needed.

Electrical Wire - Welding CableHook up WireTHHN WireRomex®

WesBell Electronics Inc
(800) 334-8400

Our Electrical Wire and Cable Website is Growing!

At WesBell Electronics we’re very excited to see the growth of our website in the tough 2011 economy. Our website offers electrical wire and cable for sale online and many more products that we offer that need to be ordered over the phone. It’s hard to keep updated pricing on copper wire because it changes every day. So we only keep our popular items available to buy as we work on procedures to get more items listed.

As more and more people visit our website we’re starting to see trends and percentages that are helping us move forward. If we get 1000 visitors we’ll see a certain amount of phone calls, orders placed online and orders placed over the phone. Based on that data, if visits increase 10 times then everything else should follow accordingly. That way we can put a budget on how much to spend to get our website to the next level.

Not only do we want to increase the visitors to our website, but we also want to increase the conversion rate to an order. So we started to offer free shipping on orders over $250 and exact cut lengths for electrical contractors and home owners who have no need for a 500 foot spool of copper wire. Like most sales people, we don’t like to say the word “no” to anyone that calls and needs a somthing specific so work as hard as we can to avoid it.

Our web design team has been working hard on the layout of our website to make it much easier to navigate for those who have a tough time using the internet and computers in general. We use the keywords that we promote so that it’s easy, once you arrive, to find what you’re looking for.

We have many pages on our website that reference welding cable and strongly promote it throughout the search engines. That puts us near the top of a search when someone types in the phrase “Welding Cable”. We aren’t going to change the term welding cable to the manufactures part number once you get to our website because we know it would be difficult for you to find.  

We appreciate any feedback you might have on our website or our products because we’ll use that information to figure out how to make your experience better. As an ISO 9001 certified company we must follow strict procedures to comply with the their standards. It assures our customers that we handle things the right way and take the neccessary steps to fix something that might go wrong. Not only do we want to avoid a similar mistake, but need to take action in order to be compliant with the ISO standards.

WesBell Electronics Inc
(800) 334-8400

Welding Cable Pricing and Specifications

We’ve been buying and selling welding cable for over 20 years and learning a lot about it along the way. There are two main types of welding cable and many similar types of flexible single conductor power cables.

Welding cable is manufactured as a single conductor wire only and usually comes in black or red. If you need a different color then most manufacturers will make it with a minimum run quantity. The second type of welding cable is much stronger, more flexible and only comes in the color orange.

It’s most commonly used on welders and power supply applications needing a 600 volt single conductor cable. It’s made with flexible 30 awg copper strands making it much more flexible than THHN electrical wire. It also has a rubber EPDM insulation which is more flexible and durable than THHN as well.

This basic welding cable comes in black or red and has a high temperature rating of 105°C. It’s rated for 600 volts and the amps for each gauge size are listed on our website to help you understand which size you need for your particular application. The sizes range from 6 awg to 500 mcm with each larger size carrying more power than the last.

The 6 awg is the smallest carrying about 75 AMPS and weighing 140 pounds per 1000 feet. THHN wire is a single conductor electrical wire and only weighs 98 pounds per 1000 feet which means the PVC insulation is much lighter than the rubber insulation because they both have the same amount of copper in them. The 500 mcm welding cable carries 695 AMPS and weighs 1960 pounds per 1000 feet. The rest of the awg sizes range in between those giving a wide range of power options.

Welding cable costs more than electrical wire because it has the rubber jacket that can withstand higher impact and a higher temperature rating. It also has more flexible copper strands that are more difficult to manufacture. THHN 6 awg has 19 strands which makes it a stiff conductor in order to push it through conduit much easier. Welding cable 6 awg has 259 strands making it more flexible to move around with the welder and coil up easily when you’re finished.

We cut each size of THHN and welding cable by the foot so that you can buy whatever you need for the job you’re doing. We also offer free shipping on orders over $250 and ship from the tax free state of New Hampshire which should each help you save money on each job.

WesBell Electronics Inc
(800) 334-8400

Information and Facts on Power Cable

Power cable comes in a variety of shapes and sizes, and can look complicated to the layman. These cables can be single-conductor, multi-conductor, as well as industrial strength or for personal use. Each type of power cable has its own advantages, which make them suitable for certain types of applications.

A power cable is categorized in three classes, 1) high voltage (for applications requiring load greater than 40,000V), 2) medium voltage (for applications requiring load between 6000V and 36,000V) and 3) low voltage (for applications requiring load below 1000V). These cables are used for feeders and other heavy machinery, along with branch circuits in electrical utility, commercial and industrial applications.

Single-conductor power cable is used in various applications such as stage lighting, locomotives, DLO and for welding purposes. Each single-conductor cable, depending upon its use, has a different rating for amps, voltage, flexibility and insulation, each having a different price-level.  

There are many multi-conductor cables; extensions cords, Type G-GC, Type W, SOOW and portable cords, each encased a rubber jacket for insulation. These cables are safe and flexible and when additional flexibility is required, there is a multi-conductor cable available for this need. The SOOW multi-conductor cable is similar to the extension cord (before the plugs are attached) and is generally used to supply power generators and tools in industries.

The least-expensive power cable of this group is the welding cable. Welding cable has a rubber jacket and flexible copper fibers and is rated to 600V. DLO cable also has the rubber jacket, is rated to 2000V and has tinned copper fibers. The DLO can carry more power and therefore has a higher corresponding price.

Remember, when installing power cable, it is recommended that you consult with your electrician. And when it is time to purchase your cable, some helpful hints include knowing the operating temperature, amperage, voltage, outer diameter (cable diameter + insulation jacket). Please call WesBell at 800-334-8400 for all your cable needs.

Installing THHN cable in cold weather

When the weather is cold, you can have problems not just with your heating bills and skin, but also with your cables. For example, the THHN cable is easily vulnerable to deterioration due to cold weather.

THHN cable is Thermoplastic, High-Heat Resistance, Nylon-Coated, therefore the name- THHN. Though it is versatile cable and does not fall under any specific application category, it is mostly used under Hook-up wire class.

Strengths

THHN cable comes in a variety of strengths. And since it is made from thermoplastic material, it is easy to heat and cool this wire many times to change its shape. But there is a limit to the number of times this wire can stand heating and cooling. It has its lower and higher temperature limits and if the temperature changes cross this range, this wire can become unstable. Temperature range depends upon manufacturers.

When the THHN cable comes with ‘High Heat’ rating, it means that this wire can be used in high temperature scenarios. These wires come with various specifications, which determine the specific applications where these can be used. For example, “Nylon coated” means that a certain thermoplastic material is used in this wire.

Coming to installation of the THHN cable in the cold weather, there are some simple guidelines that you should follow. Keep this cable indoors, and not in the outdoor harsh environment. Generally, a temperature of 65°F works well.

If keeping the cable indoors is not possible, bring it inside for at least 24 hours, before you install it.

If the outside temperature is below 14°F, then do not install the THHN cable.

While installing the cable, take care that it is not dropped on the floor, as these impacts can cause cracks in the stiff cable material.

Make sure you do not bend the cable too much, because it can cause the cold and stiff cable to break.

            Once you have installed it, this cable will work properly in environments with temperature higher than 14°F.

            All you need to Know about High Voltage Cable

            If you want to transfer large amount of electricity, then high voltage cables are your safest bet. There are various forms of these cables, and all are used for different purposes depending upon voltage of electricity and the machines for which these are used. Three types of cables are: high, medium, and low voltage cables. Out of these, high voltage cables are used when the voltage is above 1000 V. These cables are heavily insulated to prevent any risks or hazards.

            • AC power cables

            These cables are used to transfer up to 2000 V of electricity. The composition of these cables includes cross section of cable, polyethylene insulation, and conductive material like aluminum or copper. These cables are highly flexible and work well both in low as well as high temperatures. The cable layers are fused together to avoid air seeping in, as this can cause electrical discharge, thereby damaging the insulation.

            • HVDC cables

            These are specialized cables that are designed for high voltage direct currents, and thus are called HVDC cables. If you have seen a power line, then it would be easy to understand, as a power line is also an HVDC cable. These cables are helpful in carrying large loads of electricity over longer distances. After reaching the transformer, their electricity is converted to AC form. Thereon it runs with lower voltage, and is transferred to businesses and homes.

            • X-ray cables

            These cables are used to link other high voltage cables with X ray machines. These are also used to connect high voltage cables to other scientific equipment that require higher loads of electricity. These are highly flexible cables. They have a braided cover of copper wires, and are insulated with rubber. These are fused to high voltage cable to provide safety, and to reduce the hazards of electric shocks.

            All these cables are not for home use. These are used to connect high power sources to other devices or cables. If you want to buy these cables, make sure you go for the best quality, as bad cables can lead to dangerous situations.

            Using PTFE wire for High Temperatures

            Wire insulated with PTFE, or PTFE wire, is very useful. If you have been using PVC hook up wire to fight insulation melt downs, then you will be pleased to use PTFE. It cannot even get affected by a soldering iron. It has been used since the 1960’s due to its excellent performance in high temperature scenarios. Some companies also use it in classification of surface electronics.

            PTFE wire has got copper strands, plated with sliver. The silver plating, along with PTFE insulation helps the wire to sustain extremely high temperatures. It is much better than basic hook up wire that suffers from melt downs in high temperatures. And due to its great heat withstanding ability, PTFE wire comes expensive. But in case your needs are about wiring places with extremely high temperatures, it will be a good investment in the long run.

            This wire is made by following many methods. Two of the more common methods are wrapping and extrusion. Extrusion is the most common one and is done usually in the standard sizes of 24 AWG and 22 AWG. There are also some smaller sizes, where space is an important factor. The covering comes in fused and wrapped types. PTFE is also used as the outer jacket of co-axial cables.

            PTFE wires also have great resistance to moisture, flame, damage from soldering iron, and thermal aging. Apart from that, the PTFE (polytetrafluoroethylene) coating is able to resist many harsh chemicals, ozone, greases, and solvents.

            You can install these wires at many places, as they are very easy to fix. It also has low degree of power loss, and thus is great for high frequency usage. Because these wires are small and slippery, they can be used almost anywhere.

            PTFE or Extruded PTFE hook up wire has 3 types: Type E (most commonly used, and rated for 600 V), Type EE (having thicker PTFE jacket, and rated for 1000 V), and Type ET (having thin cover, and rated for 250 V). All 3 of them can be used for temperatures up to 200o C

            Basics of Bare Copper Wire

            We all know that of all the metals used all around the planet, copper is the number one metal in terms of its usage. This is because it is the most versatile metal, and it touches the lives of people in one way or the other. It has a significant role to play in electrical engineering branch in various ways. It has great conductivity power, and thus is used a lot in making electrical wire. Although there are many other available metals as well, but none can beat the versatility of copper.

            Copper wire is available in both forms- with and without insulation. It depends upon the engineers- whether they want insulation or not. Depending upon where they are using the wire, they decide if it should have insulation or not. Both insulated and bare copper wires are used in different applications. They have their use in different engineering segments.

            The bare copper wire is also called ground wire, since it has no protection or insulation. This wire is generally used as the platform for various wires and cables.

            This wire can come either in solid form, or in small AWG sizes, wrapped to make some specific gauge. Experts say that using small AWG sized wire allows more flexibility to the wire, and it bends easily around the corners. Although flexibility is a good thing, but not in all cases, so a solid form bare copper wire is preferred in many scenarios. For example, electrical contractors require stiff wires, so that the wire could be sent through a conduit for longer distances.

            Green THHN wire is called ground wire, particularly when that wire has to be used outdoors. It is used for grounding purposes to safeguard people against hazards.

            So this is where bare copper wire is used. But before you purchase this wire, you must make sure that the company you are buying it from is a good and trusted one. One simple solution is to look for this wire online. You can find many trusted online companies that can provide you the kind of bare copper wire you want.

            Types of Insulation- Hook Up Wire

            If you are using PVC hook up wire for electrical purposes, you should know about the insulation that you can use with this wire.

            UL 1007

            This wire is a form of hook up wire, which is particularly used for 300 V PVC cable that runs at about 0.016 inches of thickness of the insulation material. The popularity of the term UL grew a lot because the UL confirms that a wire can withstand the voltage and temperature that it claims to handle. Therefore, UL 1007 cable is endorsed by UL to work at 300 V, as it is mentioned on its specification sheet.

            UL 1061

            UL 1061 is another PVC hook up wire that is quite similar to UL 1007. It has 0.009 inches of thickness of insulation material. Like UL 1007, it also supports 300 V. It is generally used with the appliances that need an outlet with smaller diameter.

            UL 1015

            Yet another PVC hook up wire, the UL 1015 supports 600 V, as opposed to 300 V supported by UL 1007 and UL 1061. Since it supports higher voltage, it needs thicker insulation. The thickness of insulation material for this cable is 0.032 inches. The range of this wire is from 10 awg to 24 awg- but before the UL type could change.

            PTFE

            PTFE is another type of hook up wire. It supports insulation at high temperatures going up to 200 degree Celsius. Other PVC insulations work up to temperatures of 105 degree Celsius. Apart from the temperature difference, PTFE has copper plated with silver, and not tinned copper. This feature also helps it to sustain high temperatures.

            These wires were some of the hook up wires that you could use while working on an electric application. Some of these cables cannot stand too much wear and tear, and so they are more suited for indoor works, while some cables are rough and tough, and so can be used outdoors as well as underground. Before you buy any type of wire, you must consult your electrician and take his opinion.