# tblReply

txtReplyBody:
Ernie.

   Few manufacturing companies relize that with a robot installation you dont need an intelligant welding power source you need a process intelligent programmer and a fundamental CC or CV power source with a great interface. 

   As your application is tacks its unlikely the pulsed power source will provide any benefits as the weld cycle time will be so small the tack will be completed before the pulsed power source has warmed up. As for ramp up/down with the weld current. The robot can provide three sets of data for the weld. Therefore let the robot command a lower cost, more durable, easier to repair stupid power source. The Europeans love to purchase bells and whistles on weld equipment let them have your so called sophisticated TIG power source.

txtReplySubject:
The power source you need only requires one bell.


txtReplyBody:
For short circuit applications that require more weld energy. For example CO2 provides improved weld fusion potential when using short circuit for a pipe root and first fill pass. The first fill pass is typically where lack of weld fusion is attained. CO2 is good for short circuit on galvanealed, due to the higher voltages and more forcefull plasma . The short circuit restriction, keep the 035 short circuit weld current under 160 amps. After 160 amps the droplet size dramatically increases causing spatter.


txtReplyBody:
The first weld pass over the root is always the most critical in terms of weld fusion. If you use the E71T-1 wires welding vertical down you will have the potential for both slag entrapment and lack of weld fusion. 
  It makes sense when pipe welding when  using STICK or TIG for the root, to also do the next pass over the root with the same process. These two weld passes wil then provide sufficient weld depth to support the deeper penetrating flux cored process.

txtReplySubject:
RE: Vertical down pipe welds  and thenwith E71T-I wires?


txtReplyBody:
Mike i would use an E8018 STICK electode or E80S-6 MIG wire use 250 pre-heat and interpass. you shoud be able to grind a decent suface


txtReplyBody:
Hank

    I would not use either. Consider Plasma welding it provides many more benfits than TIG and is one hell of a lot less costly and complex as the laser.
              Ed

txtReplySubject:
RE: for tacking small fuel parts laser ot TIG


txtReplyBody:
As mentioned this product is really nothing more than a light oil. The bottom line get the cheapest. However also make sure the welders know how to set the WELD parameter to minimize spatter. 

  There is a new austrailan product from  www.spattershield.com. They use a unit that MIXES the anti spatter with with the shielding gas. I am sure that this happens before the weld and not during the weld. It sounds interesting. 
  As for the gel vasaline is great (get lowest cost) again I remind you that welders do not need these products.


txtReplyBody:
Use Lincoln L50 for steel with an argon 15-20 co2 mix, use Sandvik for stainless and Alcoa for alum. Regards Ed


txtReplyBody:
Before you consider pulsed try the following.
Your application thickness range will allow using spray transfer parameters. However instead of the 0.045 stainless wire and the three part gas mix, use an 0.035 wire with a 98 Ar-2 CO2 mix, (note it
is CO2 not oxygen).
With these MIG consumables, your welders would then set mid-range spray transfer wire-feed 550 - 650 ipm settings using a weld voltage range of 24 to 27 Volts. This spray transfer weld voltage range recommendation is lower than the typical 0.035 in. manual spray voltage range of 28 - 31 volts. The lower weld voltages will require the welders to weld at faster weld travel rates than they are likely used to.
 The bottom line: using suitable consumables and  knowing where to set them can save
spending thousands of dollars on unnecessary pulsed welding equipment.

txtReplySubject:
RE:  Should we purchase pulsed for stainless?


txtReplyBody:
Welding high carbon or low alloy steel applications can readily lead to weld issues or 
cracks. However it's  notable that many manufactures of parts and equipment
containing high strength steels do not try to match the steels mechanical properties when welding.  Frequently firms like Caterpillar will not use either the recommended preheat or post-heat treatments for ASTM or AISI steelS. 
There are many reasons for discarding heat treat recommendations. Primarily these companies benefit
from the "weld heat influence attained when multipass welds" are made on steels thicker than 12 mm.
 Many factors influence the requirements for weld heat treatment, the 
[a] application, 
[b]governing specifications or  codes, 
[c]the plate condition, 
[d] part restraint, 
[e]the plate thickness, 
[f]edge preparations, 
[g]weld consumables utilized, 
[h]weld procedures used, 
[i]weld size, and amount of weld passes required.

In the  cases when welding high-carbon steels -- where  it's not possible to  match the metal strength always use "low hydrogen", lower tensile, more ductile smaw, MIG, or  electrodes, such as AWS E7018, E71T-1 or E70S-3-6, or E80xx.

When using the low hydrogen electrodes on the high carbon, or high strength steel applications maintain a pre-heat between 200 to 400 F, the
> higher the carbon the higher the pre heat. For unknown applications start out at 300 F. If the post heat-treatment recommendation (typically
1000/1100 F) is not possible from a weld quality perspective always ensure you:
[A]. Remove rust and mill scale from weld area.
[B] Ensure that the weld locations are dry and clean.
[C]Preheat and maintain the heat within 2 in. of either side of the weld.
[d] Maintain the preheat as the interpass temperature during each weld
pass.
[f]When using multipass welds, do not let the interpass temperature exceed the preheat temperature.
[g]If possible use minimum weld joint restraints on the parts being welded.
[h]With fillet welds try to keep the maximum weld size to a 1/4.
[i]After completion, allow the welds to cool down slowly without drafts.
[j]If welding a previously welded repair, then consider cutting out the damaged area and replacing with new steel.
 If possible  try these recommendations to weld a small piece of scrap. Rememberr for a
few dollars, a test lab will perform a hardness check in the heat-affected zone surrounding the weld. If the hardness is unacceptable in contrast to the metal, then increase the pre-heat temperature and try again.

txtReplySubject:
RE: What to do with high strength steels?


txtReplyBody:
Ed, how is the preheat usually accomplished and monitored in this type of repair? Is the use of a propane or MAPP gas torch OK, followed by a reading from a non-contact infrared temperature sensor? Also, are preheats expressed as minimums, and when doing interpass welding, if the weldment is not allowed to cool for an extended time during the process is the heating effect from the welding sufficient?


txtReplyBody:
Good question.
  
 To answer this we break down the differences between MIG and TIG  

MIG DCREP reverse electrode POSITIVE. Electrons travel from cathode spots from the weld surface area on the negative grounded plate. The electrons  bombard the  MIG wire tip "the anode area" About 60 to 70 percent of the arc energy generated goes to the MIG wire tip which is being fed at a constant rate into the weld. During MIG the positive charged gas molecules (larger molecules than electrons) bombard the negative charged work providing a cleaning action on  oxides present on the work surface. This is the reason we can use DCEP when MIG welding alum.

  As you know with TIG we cannot use DCEP as the amount of energy generated at the tungsten tip would melt and damage tip. With TIG we typically use DCEN "electrode negative". Most of the TIG energy is now directed at the work. As a TIG arc is at least 100 percent hotter than a MIG arc the high heat helps remove surface oxides when welding steels. However with TIG aluminum we need the cleaning action of DC-REP to break through the aluminun oxides. As we cannot use DCREP CONTINUOSLY we use AC which switches back and forth between DC-EP and DC-EN. The high energy that results is is why the ball on the tungsten forms. By the way  you can use TIG AC to weld most metals however as the ball forms  you loose the control you get from working with a pointed tungsten. I hope this answers your question. Ed


txtReplyBody:
Best pre heat gas is "propane" In contrast to all fuel propane has most btus in outer flame. Mapp is one of those marketing sales influenced gas mixes that should not be allowed in a real world weld shop.
 Typically the preheat is the minimum, a good general rule is to keep it plus minus 10%
   Use temp stick crayons to measure temperature, measure about 2 inches from either side of weld.
  If you let the heat build up too much between weld passes, in the area next to the weld the steel grain size extends. IF you take a wooden pencil and snap it in half now try to snap one of the halfs. Long grains can lead to failure in applications subject to impact. IF YOU VISIT THE STEELS SECTION IN MY SITE EXTENSIVE DATA AVAILABLE
Good questions Ed


txtReplyBody:
When acquiring a robot a company needs to spec out exactly what it expects from the robot cell.  Unfortunately during the robot purchase few companies place emphasis on the welding process. 

With purchasing a robot you have to ask the right questions, and weld process weld data calibration is an important consideration. If the weld data is not actual then the weld procedures will have no meaning. If the weld data is not real then MIG process training and control becomes very difficult. From a liability perspective this is not where you want to be.

The problem you describe is common with Japanese CC pulsed welding units, especially when the welding equipment is manufactured by a different company than the robot manufacturer. The company that sold you the welding equipment and robot has an obligation to correct the I/O signals so that the weld data as read on the pendant is the same as the current on the power source meter.

txtReplySubject:
RE: robots and weld parameter calibration


txtReplyBody:
adding CO2 does improve weldability of a self shielded wire. CO2 is reactive and has about 10% oxygen (oxidation "porosity" potential) versus the 20% "atmospheric oxygen" it would use. 

  The bottom line you will have a surplus in the wire of elements. Will these elements cause a welding issue, I doubt it, however as we dont have all the facts just dont use the wires  in two areas, code work and applications that can endanger human life. Regards Ed.


txtReplyBody:
If you visit any foundry that makes cast irons you will note that they take no special precautions to remove defects from the casting. They typically utilize arc air gouging electrodes 3/16 or 1/14 and gouge the defects out. After arc air gouging with a constant current power source, as a precaution against the hard zone that will result in the gouged location, use a grinder to remove an additional 0.040 to 0.060 of the metal surface.


txtReplyBody:
Use "AC" GOUGING ARC AIR ELECTRODES WITH AC, with or dcstraight polarity.  Try a 1/4 6 mm electrode set at 250 to 300 amps. AIR PRESSURE amps 60 - 80 psi air 
A 3/16 5 mm electrode  IS 150 TO 200 AMPS


txtReplyBody:
Bob I have always liked Miller GTAW welders. AS i have not purchased one recently I hope you get some feed back Regards Ed


txtReplyBody:
The  most common causes for weld porosity on  carbon steel gage parts are; 
[a] lubricants on the part surface, 
[b] insufficient gas flow,  below 20 cuft/hr, 
[c] too much gas flow,  over 45 cuft/hr, 
[d] welding “plasma cut edges” which have excessive oxides,
[e] welds too small they freeze to fast,
[f] weld speeds to fast,  again welds freeze too rapidly,

There are other reasons for weld porosity,  however the relationship of the new guns and the introduction of porosity would make me examine your  guns. First check that the gun is not leaking gas, check  that the gas flow as it exits the gun nozzle is between 30 and 40 cuft/hr  

Be aware that in your robot cells the following can readily occur. You may have purchased your robots with an automated gun nozzle reamer. The reamer was designed to work with brand gun  xx. 
You keep your reamer but replace your guns with gun brand xxx. Gun brand xxx nozzle design is not compatible with the reamer. Its possible that each time you use the reamer to clean the nozzles, some of the weld spatter in the nozzle bore may be forced up inside the nozzle  restricting the gas flow holes.  

Start the shift with a new nozzle check inside the nozzle hourly. If the problem is the compaterbility of the gun with the reamer,  you can either change the guns or change the reamers.

If the weld porosity forms at a specific weld  location, watch the robot arm operate in that specific location, is the arm twisting the gas cable. Stop the robot at the specific position the weld porosity forms and check the gas flow from the actual weld gun nozzle


txtReplyBody:
If you want portablilty I would suggest trying the Handy Tig 180 from Esab. It has both AC and DC capabilities and weighs in at about 50lbs. It's designed to be used in the field and can be run off a generator. I'm currently using a Lincoln 175 square wave and it produces an excellent arc for both AC/DC tig welds, the only draw back is that it weighs 200lbs. The next machine I buy may well be a Handy Tig depending on how the demo works out.


txtReplyBody:
Stephen I am sorry I have never had this insurance
i was always under the impression a rider could be attached to your home policy Regards Ed


txtReplyBody:
Some robotic guns have an optional "air blast" line. If your guns have this, and it is not hooked up, it will suck air into the shielding gas. I have also seen faulty solenoid valves on the air blast line, leaking air into the torch.


txtReplyBody:
For short circuit its beneficial to maintain a short wire stickout to utilize the lowest possible voltage 
For low current short circuit <125 amps have the tip an 1/8 outside the nozzle with the the nozzle to work 1/2 - 5/8. 
For short circuit >130 AMPS have the tip flush with the end of the nozzle noxxle to work 5/8 
For spray have the tip 1/8 to 3/16 inside nozzle with nozzle 5/8 for weld current up to 300 amps and the nozzle 3/4 when over 300 amps

Pulsed requires a longer  wire stick out than short circuit. I would recess the pulsed tip 1/8 with a nozzle to work of 5/8

txtReplySubject:
RE: contat tip and nozzle to work positions?


txtReplyBody:
Frank

Dont forget you can use straight co2, with 035 wire up to 160 amps its a great short circ gas and over this current just bury the wire tip in the weld by using the lowest possible voltage.

 If you attach the co2 line down stream of the argon line and set the co2 at around 8% and the argon 30% you will get a workable mix. To check how effective the mix is set the 035 wire at 2 o'clock 500 ipm with 27 to 29 volts. If you have too much co2 you will get small glob transfer. If you have too little CO2 THE 27 / 29 VOLTS will be too high and a very quite spray will occur

Best single mix for you would be 20% co2, with the 25% CO2  spray is not possible, with wires <035. With 20 co2 spray is possible


txtReplyBody:
if you can get an electrician job take it.

You have been given a ridiculous task of welding 18 gage with 1/4 gaps. The sheet metal workers are the ones who should be made to look for another job. If they cannot hold the gaps to less than 1/16 can you wrap a 3 inch wide sheet metal piece (16 or 14 gage) over the gap and do  vert down lap welds. Consider argon with 5 oxygen or straight argon for the gaps they  will allow much lower short circ voltages. Also try the gap weld with your polarity changed. The bottom line is you will get no satisfaction from working with this  rubbish,  you know what to do.

txtReplySubject:
RE: Problems with MIG field welding of 18 ga s/s round/square duct


txtReplyBody:
Paul The OEM IN MANY INSTANCES MAY BE BETTER THAN THE TIPS FROM THE gun SUPPLIERS. Remember this consumable is a simple piece of copper with a hole in it. Its interesting to note that few robot tips last the potential life of the tip. 

The average robot tip is replaced prematuraly due to spatter or poor weld start / stop data. In manaual welding to prolong tip life do away with 30 lb wire spools, the tight cast and helix of these wire reels is the contributing factor in tip bore wear. The bottom line shop around and try I believe you will find good after market tips Regards Ed


txtReplyBody:
Raimo. What is an alum  challenge for TIG is a walk in the park for MIG. Any standard 350 to 400 amp CV power source will weld your application using an 062 wire. No special gun and the best MIG gas mix for you application is 40 helium 60 argon.

As for the power wave I dont believe its a single phase, if you want trouble buy it, Read the MIG and application section of this site,

As for GTAW invertors just make sure the power source you are looking at has a three year  warranty

txtReplySubject:
RE: Welding equipment upgrade for thick aluminum


txtReplyBody:
This round globular droplet attached to the wire tip is typically a result of the weld votage being too high at the weld completion. Lower the voltage can be either the crater fill or burn back voltage.

You are right about its influence on arc starts. The formation of this glob can result in inconsistent arc starts or arc start failure especially when the wire is cold.

txtReplySubject:
RE: glob of metal on end of wire after robot weld


txtReplyBody:
Sam four things will help.
[1] If you MIG power source will let you utilise low voltage (<16 volts) consider argon with 5% oxygen. This gas mix normally used for spray transfer requires lower short circuit weld voltages than CO2 or the traditional argon 25 co2 mix. The lower weld voltage will help.
[2] Try and position your parts so all the welds are vertical down.
[3] recess your coontact tip inside your nozzle at least 1/4 6mm, with your nozzle to work set at 5/8 16mm . Longer wire stick out will lower the current between 15 and 30 amps. 
[4] Ask the part designer to weld the parts.


txtReplyBody:
Raimo, The bottom line, since the nineteen fifties, a standard CV/ or CC  power source, SET FOR  spray transfer, can weld thick > 4mm, aluminun applications with optimumum weld penetration, optimum weld profiles and without weld spatter. Its to your advantage to use 1/16 ALUM wire on applications > 5mm. This wire results in lower wire cost, higher deposition  higher weld speed and its easy to feed in a standard MIG gun. One day the alum wire manufactures will wake up and provide an 052 wire which will provide benefits on the thinner gages. I believe I provided the alum wire feed and voltage range in one of the other questions on alum. Regards Ed.


txtReplyBody:
Mike the TIG gas has to be an inert argon or helium(inert none reactive gas) when using TIG. bOTH OXY AND CO2 are reactive, that is they will oxidize and react with the tungsten. The reaction with the titanium tungsten will produce oxides that will cause the the tungsten to melt at a lower temperature making it useless. Regards ED


txtReplyBody:
buy the most expensive wire feeder you  can afford that will push up to to 045" steel (spray transfer of course)  and will also accept a spool gun for alum. jobs.  you WILL regret having a small welder when you need the power on big jobs and will probably lose jobs once word spreads around.


txtReplyBody:
most TIG power sources can be used as Plasma power source that provides the current, however you need to buy a plasma console to control the plasma and pilot gas and to to attach the plasma torch to. Talk to Thermal Arc Regards Ed


txtReplyBody:
If it of any use, I will outline the latest happenings in Australia (with US/AUS dollar exchange rate, divide by 2). Last year we paid $3,500 premium for $15 million cover, this year the best we could get was $31,000 premium for $10 million cover.  It appears insurance companies in Australia don't want to touch welding companies particularly if you do on-site work at refineries, power stations, etc..  Let's hope for your sake this is not a globalisation issue.

txtReplySubject:
RE: Welders Liability Insurance - Australian example


txtReplyBody:
Grant, the more sophisticated the pulsed MIG power source the less reliable, thats a reality few can argue with.  The low pullse mode is an attempt to duplicate the aluminum fast freeze weld  patterns that result on manual TIG bike welds.  These TIG/GMAW pulsed fast freeze welds typically offer no benefits except from a cosmetic perspective.  

There is an important  relationship between pulse frequency, and the required wire feed rates,  the low pulsed mode would require low wire feed rates, low weld deposition rates, plus low peak current. 

From a robot perspective unnecessary use of the  the low pulsed mode of weld transfer would be ridiculous.  Why utilize any weld transfer mode that requires that the robot go slower, why use any weld mode that  provide less weld fusion potential for the weld. Also keep in mind the best way to control distortion is to turn up the wire feed rate and increase the robot weld travel rate. 

 The BOTTOM line for the justification of pulsed MIG for alum, you should be welding alum applications in the range of 0.06 to 0.125. Applications thicker than this are readily welded with traditional spray transfer with a CV power source that costs 60% less than a pulsed machine. Also the CV power source should last at least 10 years trouble free. Send more pulsed equipment stories, you can be sure the pulsed equipment manufactures wont tell you about their product issues. Ed


txtReplyBody:
I suspect Bug O has was making this equipment  before you were born. Its rugged, it makes a mechanized controlled weld with or without a weave, and its a hell of a lot cheaper than a robot Regards Ed.

txtReplySubject:
RE: BUGO welding carriage system...Junk or Worth a look?


txtReplyBody:
Ed, thanks again for the comments. You have been a great help. I couldn't
find an earlier post with the wire feed and voltage settings for the 1/16 alum. wire.
Are the settings different for 4043 vs 5356?
Thanks again, - Raimo


txtReplyBody:
Jaime With the 062 alum wire and spray transfer
yoU WILL be an amp rage of 200 to 350 amps, wire feed 200 to 400 ipm, 10 o'clock to one o'clock, with 26 to 28 volts. Try optimum of 275 amps at 300 ipm. 11 to 12 o'clock wITH THIS DATA It does not matter what alum series is involved. By the way your book order was delayed will ship next week. Ed

txtReplySubject:
RE: Spray Transfer aluminum for 062 1.6mm wire


txtReplyBody:
Mike you dont have many choices go with 046 its working range is 100 to 270 amps 220 tp 600 ipm  opt 170 amps 370 ipm 23 to 25 volts


txtReplyBody:
short circuit 3/8 to 9/16
spray 9/16 to 3/4


txtReplyBody:
Mark as your limitation is your low weld current out put its not likely you will see spray transfer with an 035 wire. If your weld current gets past 175 amps try argon oxygen it will resemble spray. With 035 wire use CO2 for your short circuit welds. 
 If you use an 030 wire you will get spray. use on parts over 0.85, for spray use an argon oxy mix it will allow the use of low spray volts and requires lower spray current than argon > 10% CO2 mixes. WITH 030 YOU CAN EXPECT WIRE FEED ISSUES.


txtReplyBody:
thanks for the info ed i tried this today and it worked prety good 
                    thanks


txtReplyBody:
I've used this and similar equipment (Moggy) on a number of cutting and welding applications where welder fatige was a problem.  With a little training operators soon come to appriciate them.  They are cheap automation.
PWC
(pardon my spelling :-)


txtReplyBody:
slight voltage and current differences as long as you start out with optimum settings you are in wire feed / current range, then fine  tune volts


txtReplyBody:
Ed, is there any problem using E70S6 when tacking stainless sheet metal to carbon steel if corrosion is not an issue? The E70S6 with C25 seems to form a strong weld.


txtReplyBody:
If the MIG / flux cored  arc length is set correctly for the welds and the weld travel speed is increased by more than 5%, to maintain the  correct arc length you have to lower the voltage. If the travel speed is decreased you have to lower the volts.

txtReplySubject:
RE: Relationship between MIG Voltage and Robot Travel Rates ,


txtReplyBody:
Was that a miss type? Lower the volatge when you increase or decrease speed. I would think  you would increase the voltage as the speed goes up. Help!!!


txtReplyBody:
Take a windex cleaning solution bottle and mix 1/3 light oil with 2/3 water. For the nozzle 
vasalene works.  Also be aware of how to fine tune the volts so that spatter is minimized.


txtReplySubject:
RE: needing a grasp of welding galvanized material


txtReplyBody:
sorry ed true OCV is close to 25.6 at maximum


txtReplyBody:
All this data is on this site under MIG and pulsed MIG rEGARDS eD


txtReplyBody:
sorry out of country will be able to post complete reply on 5 sept.

txtReplySubject:
RE: welding small diameter aluminum tube


txtReplyBody:
with the 22 volts you will be restricted to the 0.035 wire, 24 volts for 046 wire, helium not required and it will increase the weld volt requirements. Save your money and get something with more humpth.


txtReplyBody:
ron call me first week in sept tues or wed next week i will be back from vacation 910 313 2940


txtReplyBody:
check the weld flow rate as it exits the MIG gun cup, 30 to 40 cuft/hr is fine , heater not necessary for argon mixes, heater sometimes used if straight  CO2 is used as high CO2 RATES CAN CAN CAUSE THE FLOW REGULATORS TO FREEZE


txtReplyBody:
You did not state if you have limitations on input power. It sounds like you should look at multipurpose CV/CC power source so you can do MIG/FCAW TIG or stick. iF mig welding try and get a power source that will at last provide 250 amps 350 to 400 amps is opttimum.


txtReplyBody:
OEM vs. aftermarket tips:
Some companies do outsource their consumables. ATT is a good source for tips,retaining heads,nozzles ect.. But if you wish to extend consumable life (tips)you can also drop down one tip size: for .035 wire use an .030 tip. Most manufacturers bore tips out .008 over. I also see alot longer life from CZ tips over cu122 tips. Just a few tips.


txtReplyBody:
it makes no sense to use smaller bore tips on carbon steels. You will create issues in arc consistency and shorten the life of the tip reference the influence of bore diameter. Ed


txtReplyBody:
Ray change the analog input voltage, however before you do set the wire feed rate at its maximum for spray 500 ipm for 045 wire and 700 ipm for 035 wire. Or if you set current set 370 amps. then keep cahnging the input till you recieve this current (set 28 to 30 weld volts) . By the way the robot suppier is responsible for calibration.


txtReplyBody:
I'm thinking of buying this welder(with the spoolgun) in a month or so. I used the previous model 250 with the spool gun and was happy with it. The miller brochure rates this welder at 200 amps,28 volts 60%duty and 250 amps,28 volts 40%duty,and max open circuit voltage of 38 volts. on their graph it looks to be about 300amps,at 26 volts at about 25% duty. are they full of it.


txtReplyBody:
Fred 035 alum wire optimum amp range 100 to 200 amps 350 to 700 ipm optimum setting 150 amps 500 ipm 23 24 volts.

All my carbon steel settings apply to stainless except the gas is different and minor volt adjsutments req All the best Ed


txtReplyBody:
Most I could get was 25.6V OCV read on my VOM I have some calibration issues at both extremes of the scale; there are a couple of versions of this 250x mine is the cheaper, dual input voltage model but still nearly the largest one I can power with my existing 2phase service

 a bigger machine is not a viable option at present or reasonable near future


txtReplyBody:
between 5/8 and 3/4 you can weld with shorter however a longer stick out pre heats the wire and reduces hydrogen and worm track potential. You can weld with longer however the required increased weld voltage  makes the puddle more  difficult to control and more tendancy for globular Ed


txtReplyBody:
jd what is 2phase power,I've heard of single phase and 3 phase but not 2 phase


txtReplyBody:
Steve the primary problem is the use of an all positiion flux cored wire with high parameters for flat and horizontal welds.
The all position wires are not superior in all positions they are best used for vert up and overhead welds. 

The reason, the all position E71T-1 wires have a fast freeze slag which speeds up the weld solidification trapping oxides and slag which are trying to rise to the weld surface. These wires also have lower deoxidizer content than the wires which are better suited E70T-1. The E70T-1 wires have a thicker basic slag and are superior for high current flat/horizontal applications. Thr fore hand technique is ok and changing the angle will not make that much difference. I am aware that these wires are specified however if the company thjat specified them had one individual with welding knowlege they would allow the use of the optimum E70T-1 consumables.


txtReplyBody:
the 2 phase power is what you are thinking of as single phase its not correct if you have a double circuit breaker its 2 phase 110V is single phase, my 250V is achieved by 2 individual waves (lines) of 225V each, with the peak of one happening when the other one is at it's lowest; its simple to explain with pictures of the waves of AC current.

Sorry for the delay


txtReplyBody:
two things will help?
[1] With traditional spay transfer, try argon with one percent CO2, the one percent must not exceed 1.25% This CO2 will provide a little energy, stabilize the arc and increase the spray wire feed range in contrast to straight argon.
[2] Consider pulsed, high alloy applications are one of the applications that justify the pulsed purchase. Regards Ed


txtReplyBody:
jd2
The power I get is 115-130 single phase,for some reason i dont think the 240 is 2phase as i dont think its in sync.most utilitie companys use single and 3phase i think, if you used the two windings on a 3phase alternator wouldn't it be out of sync in one spot and not be as smooth of power. what exactly does an rms meter measure,I know they use them on inverters but they sure raise the cost on multi-meters


txtReplyBody:
jd2
that  should be 115-230 and 230 not 240,plus i keep recording the message two times, I guess I'm another idiot on the keyboard


txtReplyBody:
RMS refers to the mathmatical formula used to combine the algebraic (I think) curves. Nobody figures it out "by hand" anymore; I forgot the details. It has been more than three decades since called upon to use these details please forgive any lack of specifics

 Typical 115 volt mains power is single phase 

230 volt (USA typical) is 2 phase, and you are right the waves being 90 degrees out of phase do not coincide but there are twice as many positive (as well as negative) pulses within the same time period hence twice the energy; remember the wave isnt being made any bigger, we are sending more of them out within the same period of time. Both of them only deviate 55 volts from zero (for 110 & 220 volt alternating current) when you analize the wave on an oscilloscope.
I recall the 3 pahse is 33.3 degrees out of phase and cannot be achieved without provision specifically intended for it. I never worked with that stuff and only partly recall what I was taught, but I do know about the 110 and 220.

A "regular" volt meter simply is a needle deflected by a magnetic coil, with provision to accomondate various ranges of input voltages and test leads, etc. A true RMS meter is somewhat more complex and hence more expensive as you can see by perusal of a Radio Shack or Tektronix catalog. Often decent used equipment can be gotten through retired Bell System employees, now Verizon I think, called the Telephone Pioneers... they are handled by them when their facilities are upgraded and often can be donated to a charity or school.

Good Luck


txtReplyBody:
I have two nearby facilities one has 115 and the other measures out as 120 volts; go figure?!?

I use 115-230 and 120-240 interchangeably and I forget- sorry. I'm not using the term two phase as a purist on some kind of crusade, but because of my (limited) electrical background is more extensive than my arc welding background and I speak perhaps a different dialect. I dont mean to split hairs... I'm not that kind of a snob and that wasn't my intent... read this as a note of humility, and understand that it is not because I am unwilling to help that I direct you to any sourse of information about basic AC fundamentals to answer further questions you may have. (There are even questions in my kid's homework I find I have forgotten answers to over the years, and what's worse, there's more of 'em each year)

Good Luck
 D


txtReplyBody:
I use a 250X and spoolgun and it works well for me. I used it to weld 1/4" AL yesterday with volts at 22, feed at 7, .035 4043 wire and pure argon. Smooth arc, nice looking bead, and plenty of heat.


txtReplyBody:
You are correct, 99% of utility supplied power is three phase. Commercial customers get three phase if they require it, residential get single phase, two hot legs and a neutral. There are a few two phase utilities in the US, but it is an archaic system. RMS means root mean square, an engineer may be able to explain it better but I believe an RMS meter samples the fluctuating AC voltage and calculates the root mean square. If a meter is not RMS it is actually showing you the average/effective voltage but I believe this is derived directly from an analog measurement.


txtReplyBody:
There are many false statements here, I hope an electrical engineer responds to clarify. The power for a dryer in a house is not two phase, it is single phase. When you supply a residential transformer you only run one hot and one grounded conductor. From this high voltage primary the transformer windings on the secondary side can supply any multiple of the incoming voltage, but typically 240 V between two hot legs or 120 V between a hot leg and a grounded conductor. This difference in potential has nothing to do with phase angles or complex vectors! If you wanted to you could have many different taps on a transformer for different voltages, and in fact, some do.
The amount of Power available only depends on two things- Voltage (potential) and Amperage. Three phase presents many technical advantages in transmission, generation and motor loads, but it does not inherently provide more power because there are more "wave makers". Yes, 3 legs of a 3 phase source will provide three times the power of one leg to neutral, all other factors being the same, but a single phase source at the right voltage and amperage could always equal or exceed the three phase source, it is simply a matter of design.


txtReplyBody:
see http://www.yale.edu/ee100/class15/sld029.htm
for a simplified diagram of how you can get 120 or 240 out of a single phase transformer.


txtReplyBody:
Mike, like MIG gases there are many fuel gases available. Most fuel gases have more to do with sales and marketing promotions rather than fuel gas physiscs. The bottom line is the 3 fundametal fuels, acetylene , propane and natural gas  offer all the flame you need.

 The following logic applies to fuel gases
[1] If you have natural gas piped to your plant e its usually the most economical, however you will have to purchase equipment to increase your existing pressure and flows.

[2] Acetylene has most "btus" in the "inner flame" and provides a flame with the greastest temperature. Therefore acet will preheat the part more quiclky ready for the oxygen to do its work. If you have highly repetive cuts on parts less than 12 mm the acet will reduce pre heat times (reducing the total cutting times) making acet  the gas of choice. Note acet will use less oxygen than any other fuel gas.

NOTE IN CONTRAST TO WHAT YOU HERE FROM CERTAIN SALES REPS, ALL FUEL GASES BASICALLY CUT AT THE SAME CUTTING SPEED AS ITS THE OXYGEN (AMOUNT AND PURITY) THAT IS RESPONSIBLE FOR THE CUTTING SPEED   

[3]For those companies that do a lot of "pre heat" and cutting on parts "GREATER 12 mm" propane is the most effective gas as it has more btus in the outer flame than either acetylene or natural gas.

FUEL GAS DATA IS AVAILABE ITS WITH MIG GAS DATA. Regards Ed


txtReplyBody:
the test fr truth in your statement waould reveal a difference in amplitude of the waves as supplied from the xformer
utility service provides TWO hot wires delivering power which is 90 degrees OUT OF PHASE go test it and see 
that is why you have 110 between either and neutral and then have 220 between each other

please dont speculate and guess about things you havnt seen; I own an oscilloscope and have demonstrated the concept this has nothing to do with any transformers (test a gas powered generator)

nearly everything you presented was inaccurate as applied to mains power at the outlet

the phisics involved certainly was able to be expressed in the simplistic form of a "wave maker" and there is no need to be embarassed about it's simplicity 
What does ROOT MEAN SQUAREd mean? root of what, a tree? why mean instead of median or mode, why square instead of hexagon? I suspect your teacher was also the same person who is selling bell and whistle welders? The complex fromula termed RMS determines an average of these curves based on the mean of them. If you can explain it further and serve clarity go ahead, but we have a rule here that requires we do not give advice unless we KNOW it to be accurate. Your post contains infrimation blatently false and will cause unnecessary confusion to many participants of Ed's forum.

Thank you for understanding
D


txtReplyBody:
We are not discussing transformers we are discussing the mains power at the residential supply outlet. Changing the waveform also changes the Vrms (given waves of constant amplitude)and is the concept behind some of the fancy,expensive and often unnecessary power supplies we are being "sold". I said I was rusty on details not that I didnt know what I was talking about. However they delivered it it's a 220 volt outlet powering my welder from two "hot" lines, one red, one black, each supplying a wave form which are precisely 90 degrees out of phase from each other and which deviate from zero no more than 55 volts. Thats electrical reality.
D


txtReplyBody:
Mike,
 You are speculating and making it sound like fact.
 110 volt single phase is approx 70% efficient (maybe 65-75 I forgot details) 220 volt 2 phase is closer to 80% and three phase is closer to DC and provides something like 90% or better "efficiency"; a volt is a volt is a volt... not.

 Statistics class taught me three averages each derived from seperate formulae, the MEAN, median and mode. The RMS formula derives the answer from the MEAN average of the voltage over time. The voltage is constantly changing and is curve (waveform), frequency, and amplitude dependant, hence the complexity of the formula is necessary to provide a universally accurate quantitive assessment.
I have never encountered and am unaware of any transformers that change anything other than the amplitude of the wave (incedental effects of reactance [eg frequency dependent antennuation] etc. excepted).

Thanks for the link I will check it out it may be interesting
D


txtReplyBody:
you wrote:
the test fr truth in your statement waould reveal a difference in amplitude of the waves as supplied from the xformer utility service provides TWO hot wires delivering power which is 90 degrees OUT OF PHASE go test it and see that is why you have 110 between either and neutral and then have 220 between each other please dont speculate and guess about things you havnt seen; I own an oscilloscope and have demonstrated the concept this has nothing to do with any transformers (test a gas powered generator) nearly everything you presented was inaccurate as applied to mains power at the outlet the phisics involved certainly was able to be expressed in the simplistic form of a "wave maker" and there is no need to be embarassed about it's simplicity What does ROOT MEAN SQUAREd mean? root of what, a tree? why mean instead of median or mode, why square instead of hexagon? I suspect your teacher was also the same person who is selling bell and whistle welders? The complex fromula termed RMS determines an average of these curves based on the mean of them. If you can explain it further and serve clarity go ahead, but we have a rule here that requires we do not give advice unless we KNOW it to be accurate. Your post contains infrimation blatently false and will cause unnecessary confusion to many participants of Ed's forum. Thank you for understanding D

Root mean square, from Webster's- the square root of the arithmetic mean of the squares of the numbers in a given set of numbers Abbr: rms
Check out:
http://www.cbu.edu/~jholmes/P202/P2mag2/sld021.htm
You are confusing people by calling single phase two phase. From a three phase utility distribution system, for example, 120/208 wye, you can supply single phase transformers from each phase and derive 120/240 from each transformer. Every electrician and engineer I have ever worked with, every textbook I have ever seen, refers to this as single phase. It is derived from one coil. I suggest you get an elementary vocational textbook, all this will be covered with diagrams of transformers and the different characteristics of modern distribution systems. Unless you are the next Nicola Tesla, staring at your oscilloscope is not going to make things clear to you.


txtReplyBody:
The messages here do not thread, but I am trying to reply to these comments:
"Mike, You are speculating and making it sound like fact. 110 volt single phase is approx 70% efficient (maybe 65-75 I forgot details) 220 volt 2 phase is closer to 80% and three phase is closer to DC and provides something like 90% or better "efficiency"; a volt is a volt is a volt... not. Statistics class taught me three averages each derived from seperate formulae, the MEAN, median and mode. The RMS formula derives the answer from the MEAN average of the voltage over time. The voltage is constantly changing and is curve (waveform), frequency, and amplitude dependant, hence the complexity of the formula is necessary to provide a universally accurate quantitive assessment. I have never encountered and am unaware of any transformers that change anything other than the amplitude of the wave (incedental effects of reactance [eg frequency dependent antennuation] etc. excepted). Thanks for the link I will check it out it may be interesting D"

A volt is a volt, 120, 240 or 120/208 three phase are all theoretically 100% efficient, with the exception of I**2R transmission losses due to heat generated by resistance. For the end user, the main differences are in terms of conductor sizing and breaker sizing. There are practical limits to how much current you want to run in one 120 volt circuit. In an industrial setting three phase has many benefits, but they mostly relate to efficiency in conductor runs, load balance, and motor loads. It is not magically 25% more efficient, I don't know where you're getting this stuff.
Root mean square I have explained, if you took the MEAN average over time it would be zero, since the wave is symmetric about the x axis.


txtReplyBody:
Mike,
 I guess I deserved that and maybe worse. I really believe I understood the concept I was describing, and I appreciate the time you took to clarify by e-mail. You are a gentleman, and I must insist on returning the courtesy with apology for my abrasive tone.

You all may note my propensity to confuse measurements of angles: In conversation I often refer to a 180 degree rotation as 90.                                   .

Permit me the indulgence of explaining, at least, that I did engage in conversation with a mentor of mine (recently retired from his responsibility of supervising maintenence of all instruments and test equipment at US Steel Fairless) who did not refute my argument. As you can see, I did not achieve that level of apparent stupidity without help. You might note, however, that the spirit of the description I gave was to provide a functional, rather than accurate, understanding of that 220 volt concept and if necessary I can continue to defend it. It is desireable and necessary to communicate the fact that the wave form is not merely doubled in amplitude. Beyond that the conversation erodes to an argument over semantics. I prefer to stand with you.          .
 JD2


txtReplyBody:
Mike,
 I feel like the team that taught me let me down. When directly asked (days ago) where the 208 and 3 phase comes from the answers were evasive. I appreciate your patience and perserverance. At last it all fits.
D


txtReplyBody:
this type of information is attained at any weld distributor that sellS bronze filler metals. 

typically  phosphor bronze is sold for good color match, aluminum bronze for strength, silicon bronze for weld fluidity


txtReplyBody:
Guys, the phase subject has been done to death. In the sixties and seventies when you went for a MIG course THE INSTRUCTERS at the weld equipment manufacturers used to train the weld decision participants on phase - transformers rectifiers and diodes. When the training participants left the MIG training course they knew how to build a MIG power source but they did not know how to operate it.
The bottom line it's more imopotant in this industry to understand the weld process, the consumables,  parameters and process control requirements rather than whats happening to the welding input current, so please enough with the phase issues. Regards Ed


txtReplyBody:
Ed,
 At the expense of your sense of humor and good nature are you saying this discussion should be phased-out?
JD2


txtReplyBody:
Al, its a shame in the North America that the primary MIG wire used with argon mixes is a wire that was designed to be used with straight CO2. The weld reality is use the E70S-3, its a  lower silicon wire designed for argon mixes. The E70S-3 contains less silicon resulting in less surface oxides and scale, and especially important when welding coated metals (GALVANEALED GALVANIZED the E70S-3 can reduce micro cracking potential as it has less zinc/silicon reaction. Be wary also of the different levels of silicon available from different wire manufactures. For example you may find that a National Standard wire (a wire I dont recommend) has more silicon than an equiverlent Lincoln wire.  By the way the automotive industry is the reason the welding industry is using the wrong MIG wire, the automotive screw up is discussed in my book " A Management and Engineers Guide to MIG".  Regards Ed.


txtReplyBody:
its a marketing induced fuel gas that in reality offers no more benefits than propane


txtReplyBody:
JEFF 
035 should be considered the smallest practical wire size, smaller wires <030 
(a) cost more 
(b) dramatically reduce the weld deposition rate potential, 
(c) cause extensive wire feed issues,
(d) for fillet welds larger than >3/16 the small welds add to (a) lack of side wall fusion potential (b) porosity potential. If you feel its important to understand the MIG process you may want to consider my MIG Training book. Regards Ed


txtReplyBody:
Mike the following may help

[a] THE primary issues with most drums and reels are helix and poor wire joint connections. You can apply the AWS SPEC data to these issues and if you have problem ask the wire suppier for a full refund, then dump him.
 [B] i like to avoid  both Hobart and National Standard WIRES i HAVE HAD TOO MANY welding issues with these products. Compare what you have with a Lincoln L50/56 thats one product Lincoln has yet to screw up.
[c] All robots should have wire straightners and as noted in my management book on MIG, operators should be trained twice a shift to adjust the wire tension to improve the wire helix.
[d] For short circuit applications ensure the WSO IS NO MORE THAN 1/2 FOR SPRAY NO MORE THAN 3/4. 
[E] ON LONG WELD RUNS OR TROUBLE AREAS ADD IN MORE ROBOT POINTS


txtReplyBody:
Branden call Huys Industries Canada 416 747 1611
they have been working on the optimum tip, I dont know if its ready yet, I also read somewhere about special high frequency pulsed equipment that works well on thin gage alum If i find the data I will post it here. Ed


txtReplyBody:
I know this steel is welded with an E80XX AND IF YOU GO TO MY STEELS PROGRAM PICK A TOOL STEEL AND AT BOTTOM OF TABLE YOU WILL FIND A TENSILE STRENGTH TO HARDNESS CONVERSION which will give you the hardness of the weld. Unfortunately my ASTM steel data book is at present in storage

txtReplySubject:
RE: Hardness Number for High Strength Steel


txtReplyBody:
refer to steels and weld consumable section of this site. No its not any more difficult, however preheat and interpass temp as recommended along with the electrodes in he steel electrode section


txtReplyBody:
As the information in the steels and electrode section of this site indicates a preheat of 400F WAS required also ensure interpass temp does not exceed the pre heat temp. Any E70 OR e80 low hydrogen electrodes may be used. Your gas and wire
are OK.


txtReplyBody:
George. First your wire  1 mm is likely 035 The european decimal method typicallt rounds of so an 0.9 mm (035 becomes a 1 mm.

If your power source only puts out 160/170 amps this is not sufficient for spray transfer. Its is sufficient for short circuit and globular. A typical wire feed setting on your power source fo 160 amps would be the 11 or 12 oclock setting. the voltage I suspect would be the #2 or three setting. 

WHEN YOU MAX YOUR WIRE FEED YOU ARE NOT GETTING ENOUGH WELD CURRENT THATS WHY THE WIRE STICKS

TO GET SPRAY TRANSFER YOU NEED > 200 AMPS AND > A MIN OF 26-27 VOLTS. Borrow a volt ap meter and crank your power source volts and amps wide open then you will likely find that the current you attain are short circuit,

To improve your opportunity to attain spray you would have to use the 030 WIRE. REGARDS ED. 
ps. my MIG training book explains all this.


txtReplyBody:
typical tip bore clearance is 0.007 - 0/010
Do not use smaller tips especially with a robot
As most tip issues are not bore related using special alloy tips is TYTPICALLY a waste of time and money. I know about this subject I have a pattern on special ceramic Cu tips, 
 Reducing the wire helix with wire straightners that are adjusted at the start of each shift will do more for tip bore wear than using special alloys. Most tip issues in a robot weld cell result from poor weld start/end data.Use the robot weld start/end data in my MIG train book to reduce tip changes. In a robot cell its logical in a high weld volume application to make a tip change at lunch time. Bottom line a new tip at the start of a shift and a tip at lunch time. $2 a day for weld consumables per robot. Put your focus on the issues that are causing the tip problems Call me if you need more help Regards Ed


txtReplyBody:
ask a question that we can understand and we will all be glad to assist you Ed


txtReplyBody:
Our experiences with the aforementioned Wire Suppliers ahve been directly opposite of your experiences ITW/Hobart and NS have worked diligently on their problems and have arrived with suitable solutions

txtReplySubject:
RE: Wire manufacturers and AWS A5.18 Loop holes


txtReplyBody:
I hope you do not work for one of those companies. I repeat I have had numerous issues in "the past" with Hobart and National Standard carbon steel wires. You did mention that you  also had problems. As both companies have been likely making MIG wires before you entered the work force, ask yourself how long does it take to get it right, After all making a MIG wire is not rocket science. Thanks however for your point of view. Regards ED


txtReplyBody:
Miller has a good book on TIG they have mastered this process as it only has one control.


txtReplyBody:
Joesph good question

In many companies an attempt at weld quality control is made through the companies compliance of either a weld specification or procedure. 
Most weld procedures are too broard, not practical and the procedure spend more time filed away in a cabinet than they do on the shop floor.
The reality of most specs is their focus is on the requirement of the "finished weld". With most weld specs and QA WELD programes the message from the QA department is "we will tell you how we want it, but we dont know how you should do it"  
For weld manufacturing controls, I developed a seven step program to establish  effectice weld process controls. This program in contrast to your welding specs provides the process requirement for process controls. The program is  in my "Management and Engineers Guide to MIG" book  
Good Luck Ed


txtReplyBody:
As a robotics company involved in MIG and other types of welding, we have experimented several different products and have finally settled on Spatter Shield as the best overall performer in the area of spatter resistance and removal.  The fact that the product is delivered with/by the shielding gas is a real bonus because is ensures a continuous protection for the nozzles, tips, workpieces, etc.

Have a look at the product specs and give it a try

http://www.jcdrobotics.com/spa_shd/spat-shield.htm

Best regards

Gerry Lemay
JCD International Robotics Corp.


txtReplyBody:
Ed, I don't know the alloy of aluminum engine blocks. The weld repairs included todays race car engines as well as antique car and motorcycle engines.
Johan


txtReplyBody:
I had the URL to a site which had a military training circular about various welding procedures, but lost it when my hard drive suffered a calamity. The site provided an excellent overview and outlined basic safety precautions should you decide to experiment on your own.

Im sure it's out there somewhere; good luck.


txtReplyBody:
i couldnt even think of providing advice on an unknown alum alloy, many alum grades can be welded, however welding may not be recommended, The bottom line with these grades is failure can occur after the weld. I think possibly the alum  engine block may be in this category. Ed


txtReplyBody:
Jack with pulsed MIG on "all position" stainless applications I find the process beneficial on applications in which the stainless wall thickness is <6mm.In your thickness range, without question the most logical weld method would be the use off all pposition gas shielded flux cored electrodes. The FCAW process will in contrast to pulsed MIG will provide the following benefits;
* Higher weld deposition rates.
* Superior weld fusion.
* Easier to use  as less skill required.

                  Regards Ed.

txtReplySubject:
RE: Pulsed MIG of flux cored for Stainless Pressure Vessel


txtReplyBody:
Jack, try ESAB's "Shield Bright" FCAW wire (the old Alloy Rods brand) runs very well.  You can check out their web site and find all of their consumables.  My understanding of Alloy Rods / ESAB, was ESAB came in and bought them out, but didn't change the chemistries of the products.  You should be able to obtain pretty high deposition rates with their product...we seem to do well with it.

Steve


txtReplyBody:
Dave As you RT the pipe AND WELD and saw nothing unnaceptable, and the pipe and weld was relieved of their stresses, then its logical to assume the weld and base material is fine. However you are dealing with an auditor who likely knows more about the code than he does about metallurgy or welding,  so its also logical to assume that in his world there is only black and white with no room for grey, Good luck Ed


txtReplyBody:
Ed I currently use co2 on all of our products. We have found that it gives us more penetration. But I would like to try another type of gas to try to increase the travel speed and reduce the spatter. what would you recomend?


txtReplyBody:
This E70T6 DCEP 5/64 wire needs to run around 380-400 amps 24/25 VOLTS (WSO 3/4) to optimize THE weld dep. If you use steel back up bars the steel should be thick enough to withstand the high weld current for the first pass. I think >6 mm would be suitable. Otherwise what can I say, only with these wires try not to breathe to deeply while welding.


txtReplyBody:
All the data you need is in the gas section of this site go to MIG/FCAW data then takr the gas link


txtReplyBody:
Have you tried going to Co2/Ar mix gas and a smaller wire diameter then trying to kick into spray mode? Also, are you using any bevel? Your supplier should be able to help you as well. But as stated, you cant expect bigger wire to be the answer with the machine limitations.


txtReplyBody:
Seriously? This sounds much less expensive than what we currently use but I must ask, does the oil/H20 mix not pose a contamination risk? How do you keep it from separating? Does vasaline work as well as nozzle dip?


txtReplyBody:
Thanks Ed for your recommendations. I have read your books and keep them in my library for reference material. We initially started this evaluation since our spools supplied caused serious wire placement issues while welding cylinders. We UT 100% and any wire flip out of the joint may fail the weldment. This gets costly very fast. We are presently investigating wire straighteners but are also stuck with the Lincoln Powerwave which has a default inching speed of ~80 ipm. This speed does not allow operators to adjust anything quickly (we have a hand held 24volt device that can manually change the wire feed speed but this is also time consuming). Our electrical stickout is at the minimum 3/4" - 1" due to joint design with u and v-grooves. So ultimately we are looking at the wire manufacturers to supply a wire that will give superior "wire placement". All the suppliers I listed are working to try and supply this accurate wire. I was just curious to hear if we were the only ones experiencing these issues. The real frustrating point about this all is how quickly the wire supplier will point out that since we are using the "straight" wire that the cast/helix specification of A5.18 does not apply to them. When asked how should we measure this, they point out that it takes "specially trained personnel" and is not easily done in the field (they even point out that there reps are not capable of this). Sorry about the rant but when this wire evaluation is complete I may be able to share more light on "straight wires".


txtReplyBody:
Paul its a simple task that took me twenty yeasr to figure out then I decided to write a book or three. The answers you need are found in two of my books the Management one and the MIG training one. If you need more data call me at 910 313 2940


txtReplyBody:
Guys I spent over 1000 hrs last year building this site.  All the data you need is either at this site or its in my books. Regards


txtReplyBody:
i think your pre heat is too low bring it up to 400F maintain this also as the interpass temp. This info is avaialble in the steels/weld conumables section under AISI steel Regards Ed

txtReplySubject:
RE: welding 4140 and 4130 H.S.L.A. steels


txtReplyBody:
If you know how to set the equipment which is what my MIG process control training manual with 160 process questions will provide, it should take about 30 to forty hours of actual hands on practice to aquire the MIG skills. I have trained hundreds of people who have never MIG welded to MIG weld in four. And the four day program was a 25 mm heavy frame applications with a high degree of weld difficulty for the 5/16, long  fillet welds.
 
A low cost way to achieve what you desire read and learn the MIG Train book, go to a low cost night school offering a MIG cours. at the school you have the equipment. Follow the teachers skills technique advice and use what you have
learnt in the book to master the equipment. In a short period of time, due to your expertise at controlling the equipment, its likely you will know more than the instrutor. Regards and good luck. 
Ed
>


txtReplyBody:
For s given eire feed rate by going faster you need to shorten the arc length by lowering the weld volts


txtReplyBody:
Mike I believe yout spec is 
  not correct or incomplete


txtReplyBody:
wITH any questions dealing with steels  you have to provide SUFFICIENT information. No steel nick names or trade names. If its a North American product it will have an ASTM, AISI, CSA designation and if it has you will find info on it in the steel section of this web site.

txtReplySubject:
RE: joining EN 19 toE500Steel of YS500mpa Cvn-51


txtReplyBody:
I am very interested in getting an answer to the above question


txtReplyBody:
I think you will find that as long as you are welding steels less than 1/8" short circuit is your process. You can use it in all positions. CO2 will provide the most penetration. If you are concerned with penetration, set your procedure up so you can maximize the weld capabilities. Think double bevel, root pass, then cover pass(es). I am sure ed will correct me if I stated something incorrectly.

txtReplySubject:
RE: Quality of short circut transfer weld


txtReplyBody:
Don I believe you have missed the point of the clock method. First the chart data on MIG equipment, (when its provided)is rarely practical. The clock method focus is on the relevance of wire feed control. You are teaching welders the wire feed and  voltage range along with optimum settings and most important for any trainer you are giving them a method which is easy to rememeber. 17 cups of coffee (17 volts) at I0 O'CLOCK. Or should we tell them to rember 140 amp at 210 ipm with 17 volts.

How simple is 17 cups of coffee at 10 oclock for the optimum short circuit position. The welder has a wire feed position he can readily remember , he can convert that the third turn wire feed position to ipm, 3 x 70 = 210 ipm for his state of the art digital feeder. Welders need process expertise, If your students are confused by this simple method I suggest you examine the way you teach. Regards Ed

txtReplySubject:
RE: GMA Welders changing with technology


txtReplyBody:
You never read on my site that short circuit is an inferior process, you will read on my site what the application considerations are for short circuit and what the application thickness should be. Many people who visit this site simply dont spend sufficient time to read all the facts.


txtReplyBody:
I'll wait until I get your newer version video (I have a very old one called mig welding made easy) and watch it and see if I "get it". If not I will reply and make sure I do. So do you feel the charts on the machines are innaccurate?


txtReplyBody:
innacurate may not be the right word are they optimum "no" Why do you thing so many pre-programmed weld schedules that have gone into pulsed equipment are INADEQUATE, cause weld issues and and have gone through numerous changes. Even the settings in the AWS MIG procedure guidelines are so far of what they should be they should not be printed. Compare and get back to me regards Ed


txtReplyBody:
if you are prepared to pay a price and know how to use it consider  "alum bronze"


txtReplyBody:
Don the bottom line is they do not need metal cored. For optimum control of the 10 gage to 3/8 weld, an 035 MIG wire using argon with 10 co2. (035 wire feed 500 to 600 ipm) To minimise distortion weld on down slope with lowest possible spray volts. For the 3/8 work the 045 solid wire with the same gas will be fine on clean metals minus mill scale.  Ref ASME, METAL CORED OFFERS nothing.  If they insist on metal cored just use the wire diameters and gas mentioned Regards ED


txtReplyBody:
MIKE
the 2% is thorium which I believe changes the melt temp of tungsten. Pure tungsten is recommended for alum because of the AC polarity. used for alum. Once the AC arc is struck the tip of the tungsten melts and turns into a controlled round shape. Pure tungsten is better suited to handle AC. With AC the polarity changes between RP/SP. Reverse electrode positive places much more heat at the electrode tip and the round tip end (larger diameter) can take the heat better than a pointed tip


txtReplyBody:
Thanks for your reply. It seems to me that 85/15 would be a better gas mix for thier heavier applications, they have the 2 gasses piped throughout thier plant and can easily adjust the mix. And for thier thinner applications 92/8 for lower volt needs. Why is metal core such a hit?!!
Your thoughts on the above?


txtReplyBody:
My 2 cents worth...
In the past 6 years I've been the welding engineer at 2 fairly large facilities (>300 feeders).  Both places had way more "old feeders" than "new".  Although we often by digital feeders the vast majority are not.  At my last employeer, before I learned the simplicity of the clock method I throw away hundreds of thousands of dollars $$$ on new Lincon Powerwaves.  When I think back, I could have spent the money on process training and shown the company a REAL cost savings.  (maybe that's why I'm not there today?  I digress)  I have Miller, Linde, ESAB, Hobart... feeders that are over 7 years old (some way over).  The only successful teaching method I've found is the clock method.  It works reguardless of the age of the equipment.  
If I could give advice, one welding educator to the other, I would say save your money.  Don't bother investing in complicated Mig equipment.  Keep your old Lincon CV-300 and LN-7 and teach students how to set a machine by understanding wire feed speed and voltage.

As for the worlds greatest Mig chart...
It's pretty simple to make.  I hung one on every feeder (300+) in my plant.  I have a bulk gas system so I don't need to reference shielding gas.  We only use 2 wire diameters, so that info is minimal.  I included a graphic of the volt meter and the wire feed meter to make it simple and the wire feed speed ipm for digital feeders.
I've said too much... Have a good day!
PWC


txtReplyBody:
compare your chemistry with the steels in my steels section and use that welding data


txtReplyBody:
Apparently I miscommunicated. Although we do have one of the new GMAW machines with all the bells and whistles, all of the other 21 GMAW machines we have are basic. I too believe that the basic machines have the most to offer a learner. My point was that the new basic lincoln GMA machines have digital readouts instead of the dial readouts. That being said I have gotten the point that the oclock method is an easy to reference method, I just needed to learn to teach it in a way that students could adapt to all GMA machines, regardless of readout type. After reviewing once more I realized I had "missed the point" and now I "get it", more importantly, my students now "get it" too. Thanks for the feedback!


txtReplyBody:
Ref the weave: Adjust the weld weave so no scalloped edges appear in the weld edges. The weld fusion edge lines should be straight. This is achieved with programming maximum weave osscilation with minimum forward movement, along with minimum left/right dwell times. The straight edges of the weld will be an indication that consistent edge fusion is attained. Thanks for the kind comments on the training books. Regards Ed


txtReplyBody:
Well, that's great for a sin weave, but what about the inline weave?  Is it beneficial/detrimental?  And your book again came in great use today again.  They are not kind comments (and this is not butt kissing) but keen observations of simplicity and a common sense approach to welding.  I have been involved in robotic welding for 7 years, 3 of which has been integration and installation.  I am still learning - but this book is gold.


txtReplyBody:
Rick by inline do you mean the robot goes back and forth in a straight line motion. If so this "straight whipping" technique is common with manual welders. Its actually a skill developed by stick welders when welding gaps. Used in MIG welding, it will on >3mm applications that have no gaps produce "inconsistent poor  weld fusion".
Thanks for the book comments It picks me up. Ed


txtReplyBody:
The gas shielded flux cored wires can absorb moisture therefore theses low hydrogen products  should be stored in a warm dry enviroment. The self shielded flux cored wires are not low hydrogen products  You can bake the gas shielded wires typically 300 to 400F for a few hours, this  will reduce moisture levels attained in the flux. The best advice for baking will come from the electrode mfg.

txtReplySubject:
RE: moisture/humidity protection concerns for flux core wire


txtReplyBody:
Center line cracks typically occur in a weld due to innsufficient weld throat. As the weld center is the last area to solidify it needs sufficient weld metal to withstand the shrinkage stresses that occur (especially with clamped parts)
Put more weld wire in the weld, or  slow down the weld travel rate. 
 .BY THE WAY i DONT KNOW WHAT ALLOY 20 is but welding 516 as indicated in the steel section of this site is usually welded with E70S-X E71T-X E70XX electrodes.


txtReplyBody:
So would you suggest storing FCAW electrodes in an oven or just baking them before use as a precaution.


txtReplyBody:
Yes, I get your point and that is what I have been teaching, however, the new lincoln GMAW machines do not start at zero " per min. at the 7 o'clock position they start at 50 " per min at the 7 o'clock position. They dont have a zero " per min setting at all. So, since 700 IPM is thier max setting at the max setting one would think the 12 o'clock setting would be 350 IPM but its not. I have reluctantly had to stop teaching the o'clock settings and just teach the IPM parameter settings you suggest because of this. I guess my point is that they have messed the IPM dial up so much on the new GMA welders that I didnt want others to make the mistake of assuming 12 o'clock is automatically 1/2 of the 700 IPM max setting. On the new ones 2 o'clock is. I dont know why they went to this but they did. Thanks.


txtReplyBody:
if the FCAW wire is stored in a "dry low humidity enviroment" where the temp is over 60F, and THE wire was purchased within the last twelve months (in its origional container) the wire should be fine. The bottom line with concern for hydrogen content is of course the application. If the products are used for code work and there is a question about the electrode condition my position would be dont use the wire, use it for some less demanding weld application. If you have to use the wire then baking gets rid of moisture. Ed


txtReplyBody:
Don I am glad to see someone out there has seen the light. All the best Ed.


txtReplyBody:
Don you have missed the point, with the clock method you dont even need a wire feed control the wire feeder can be digital. With the clock method you are teaching the weld parameter ranges. Think about it, a student may have to use a wire feed control that provides 1000 ipm. My method teaches the student to check out the wire feed control and place the control in the correct position.  If you need further info call me  970 988 1169 will explain.


txtReplyBody:
Don there is a relationship between TIG and MIG, THE WELD CURRENT that a part can support. With GTAW i look for the weld current requirement then ensure the tungsten size selected provides the range I desire. Again with TIG I will only use pulsed if the weld benefits from the pulse. Miller has a decent book on TIG. Regards Ed


txtReplyBody:
Sorry, the wire diameter is .035", gas is 92/8.

Rick


txtReplyBody:
The gun angle has nothing to do with spatter, a point you should be aware of with the training book. The parameters you state are in the spray range, however do a check on the amp meter to ensure you are above >200 amps. Its likely your voltage needs to go up a volt or two, REMEMBER VOLTAGE IS INFLUENCED BY MANY FACTORS. Increase your weld volts till no crackle, then decrease volts till crackle sound starts. 
Most fillet welds use a 40 degree angle with 15 to 20 degree push. The push angle also applies to butt welds.


txtReplyBody:
Sorry Scott  after MIG welding for forty years I dont believe in anti spatter, if your custome has to use it oil and water works. Why not sell your customer on how to improve his welding so spatter is no an issue, it will be more profitable in the long run.


txtReplyBody:
Tom the most logical weld choice for your alum application is a single phase 250 traditional CV power source with a one pound spool gun, feeding an 0.046 alum wire. The 1/4 to 3/8 part thickness makes this an ideal candidate for traditional spray transfer. The only thing you will get from the pulsed equipment is a higher bill. Regards Ed

txtReplySubject:
RE: Pulsed For Alum, is it the best process?


txtReplyBody:
Thanks, Ed...a quick followup- in comparing a 250A powersource to a 300, what would the maximum wire diameter/ practical base metal thickness of aluminum be for the 250 Amp...would hate to save a few bucks initially, but be limited to nothing larger than the mentioned sizes.  'Preciate your expertise...


txtReplyBody:
Tom get the 300 amp, in the long run it will provide more application potential. The alum data you need can be found in the alum section under "steels and weld consumables". The 046 alum current range is approx 170 260 amps, steel 045 requires > 250 amps.


txtReplyBody:
Dave, with argon 15-20% co2 you get spray with >200 amps, >420 wire feed rate. 27 - 30 volts. 

          This data is available in my MIG train book. Regards Ed


txtReplyBody:
The weld reality is that you guys need to pull your head out!  Ed can you tell me WHAT the relationship between pulse frequency and wire feed rates and what is it importance for low pulse welding.  Maybe you should understand low pulse welding before you pretend to be an authority on it.  Low pulse welding IS an attempt to mimic a TIG weld look.  To some customers, cosmetics are important, that's why they TIG weld in the first place.  Low pulse will give them nearly the same appearence with an increased production rate over TIG.  Oh, have you tried to find any good production TIG welders lately?  Low pulse also provides the ability to very precisely control the heat input to the part.  The last time I checked my calculation, if you increase travel as well as wire feed, the heat input is the same.  This is especially helpful for the occasional customer that does not have absolutely perfect part fit up.  We all know that nobody that welds aluminum has fit up problems.  Low pulse also gives the customer the ability to weld thinner materials without having to use a CV short arc, thus eliminating spatter.  As far as your opinion on pulsed welding goes, I don't know what kind of customers you deal with, but obviously they are not concerned with increased travel speeds, reduced cycle time, less weld spatter, or lower heat input.  I understand that CV has it's place,(usually in a small shop or somebody's garage) but maybe if you had an open mind about new technology and spent some time using some state of the art equipment, you would find that it does do what is advetised and provides real benifits to the end user.


txtReplyBody:
treat this application lke a regular carbon steel weld, as the material is thin no pre heat is required, use a regular E70S-X WIRE with an argon mix gas.


txtReplyBody:
ref 1 . An argon 15 to 20 CO2 is fine, if the gas suppliers dont have a mix in this range find someone who does. Yes it may come as a surprize that its up to you to educate your suppliers, after all you guys do the welding they simply sell welding products.

 2. The reason they sell metal cored wires is it makes more money than a MIG wire, I think salesmanship has something to do with it. Regards Ed.


txtReplyBody:
Thanks for the quick reply. I finally have been able to get them to start stocking 80/20 Co2. One more question, would the only advantage of using 85/15 over 80/20 be lower welding voltage parameters in spray mode? 
I hear alot about the metal core and have ran it on my track mig then switched to normal wire and cant really see a difference even after destructive testing other than a slight appearance difference on the weld face. I know it is more expensive. I hear it's easier to run. Comments?


txtReplyBody:
chris, dont know what happened to the messages above, we have had excellent luck on this type of application with .035 wire electrode, 92Ar/8Co2 gas, push dont pull, 17 volts/210 ipm wire speed is a good starting point for this application (eds numbers)but spend alot of time getting your parameters just right and it will help ALOT,(practice and adjust wire speed first, you will find alot of help on this site and in eds book if you have it, do a good job tacking, try not to tack where your welds will begin, move quickly with a slight motion to help prevent burn through, try to set it up so you can weld 1/2 diameter of pipe at a time with this size tubing, good fit is crucial so spend your time prepping and it will really help your welds. Remember, the end of tubing will melt faster than the side will so practice concentrating more heat on the tubing side and less on the ends on those particuler joints. Good lick, I am sure you will do fine!


txtReplyBody:
Thanks Ed & Don.
I have three more questions. Don, you said 17 volts 210 ipm for settings. I have a Hobart Handler 135, how do I know what volts I am at and the same with wire speed? It has the four individual voltage settings, 1-4, but does not give any indication of what the actual voltage is. And the same goes for the wire speed, it has a range of 0  to 100 without any indication of what the actual wire speed is. Also, would 0.030 wire be okay, as the 135 can not handle 0.035 wire. Finally, is there any advantage to using ER70S-2 wire over ER70S-6 for out of position welding.
Thanks for the help.

Chris


txtReplyBody:
23 to 30 volts have you considered my fcaw book it may make a good xmas present Regards Ed


txtReplyBody:
Mike take no notice of the metal thickness recommendatios for these low amp power sources consider them a practical unit for welding up to 1/8. Many people who buy this MIG equipment  soon realise it belongs in the toy closet.

txtReplySubject:
RE: Millermatic 135 vs. Lincoln SP-135 Plus product comparison


txtReplyBody:
Greg Not familar with the 190 GRADE. Let's say its a high carbon 2.5 inch metal welded to a standard low carbon grade. TFirst without pre heat use a standard e70s-x wire with yout gas mix. Test the weld with a hardness test, plus a macro and pull test. If problems occur use 400 F preheat and interpass temp. 

If problems occur plan B. Consider  an austenitic  309 or 312, The 312  may be better for its crack resistance.


txtReplyBody:
Marv I would recommend you order my MIG process control training book so you dont have to play around or guess about weld  parameters. Your wire feed setting is spray, your gas is OK, there are fIVE things to look at 
[1] your voltage may be a little low it will depend on the weld speed you have set. Turn up the volts till quite spray sound (no crackle) then reduce volt till crackle sound starts. 
[2] Who makes your MIG wire?  inconssitent wire chemistry makes for inconsistent welds, especially noteable on long welds. 
[3} How do you know thats its really 550 ipm did you confirm that the wire feed is actual? 
[4] Is the wire slipping or skipping during the weld? 
[5] In the area in which you have a problem, stop the weld and release the wire feed rolls and pull on the wire, this will tell you if you have   wire tension or contact tip (bore) issues. Regards Ed


txtReplyBody:
Wire diameter, material (aluminum maybe?), gas mixture used, gas pressure, and parameters used would be helpful information.

-Rick


txtReplyBody:
YOU NEED TO ASK THIS QUESTION TO A MANUFACTURER
OF NICKEL ALLOYS (INCO)

txtReplySubject:
RE:  PROCEDURE FOR WELD REPAIR OF MONEL K500 CASTINGS


txtReplyBody:
your weld data should be, 
[1] weld start 350 to 400 ipm with 23-25 volts, minimum arc start times of less than 1/3 of a sec. 
[2] for the weld a wire feed 550 ipm. 26 - 28 volts7 for 1/4 fillet 20 ipm for 3/16 which is big enough for you 35 ipm [3] for overlap weld at the end use same as weld start.  
You can put in as many weld schedules as you want the point is you only need these two. All this data is in my MIG train book, regards Ed


txtReplyBody:
CHRIS. SET YOUR WIRE FEED AT THE 10 - 11 OCLOCK POSITION
USE THE FIRST THEN SECOND VOLTAGE SETTING, CHOOSE THE VOLT SETTING THAT PRODUCES THE BEST CONSISTENT CRACKLE SOUND. THEN ADJUST YOUR WIRE FEED BY A 1/2 TURN IN BOTH DIRECTIONS TO MAKE THE CRACKLE SPUND THE MOST CONSISTENT. ed


txtReplyBody:
welding consumables and procedure are avilable in advani-oerlikon.pl give thickness and job details to give recomendation. tks and regards.   raghu


txtReplyBody:
sa738 gr b welding is not difficult if you fallow the weld procedure . pl give more details on the job , thickness position process etc to give suitable WPS. regds. raghu.


txtReplyBody:
E-900 gouging electrode are more suitable for gouging application.you can also use A 902  air arc gouging carbon electrodes with ,CAG9 OR CAG 15 TORCH.  regds.  raghu.


txtReplyBody:
Thats true, and easy when you get used to it. time it for 6 seconds and multiply times 10. The only issue is that some machines have a start relay so they dont feed the true set ipm for a couple of seconds to allow gas to purge the weld. So set your machine, hit the trigger, when the wire begins to feed at the set rate time it for 6 seconds then multiply times 10


txtReplyBody:
I noticed that 80s-d2 has a preheat,interpass and cool temperature of 275 degrees. Can this be used without preheating? Also, what benefits would be gained from quenching with oil?


txtReplyBody:
Use 309, best gas for spray argon 2 CO2, second best gas argon 2 oxygen use regular argon CO2 flowmeter set 35 to 40 cuft/hr


txtReplyBody:
Lincoln sells a hand held unit for >$650, it used to have a cheaper handle and sold for $200. The shiny handle they now provide is costly. However when you are a monopily you can charge what you want. Ed


txtReplyBody:
The question is the same as the one previous. 
[1] weld with E70S3 WITH AN ARGON MIX SUITED TO SHORT CIRC OR SPRAY.
[2] As the application is thin, pre or post heat will not likely be necessary. If uou are concerned ABOUT THE WELD MECHANICALS after welding have the welds  tested without heat 
treatment. The reasons heat treat is often not used on high carbon thin metal is [a] the thin tubes heat up quickly and [b] stay hot for a long period after the weld. This reduces the concern for hydrogen input to the weld  and has an annealing influence.


txtReplyBody:
Not a bad idea about your book.  I'm going to order it shortly.  Concerning weld technique, though.  In one of your articles you mentioned weaving and horizontal fillets.  My welding instructor has instructed us to use a 'c' shaped weave for welds in this position.  Should I just use a push angle and a slow steady speed or what?  What's the right way to do this without undercut or other weld defects?


txtReplyBody:
don check the weld current at this wire feed setting and let me know what you are getting


txtReplyBody:
SET THE MIG WELD ARC LENGTHY FOR THE CONSISTENT CRISP CRACKLE SOUND. TLL THE WELDER TO MAINTAIN THE NOZZLE TO WORK DISTANCE AT 1/2 TO 5/8 AND DONT GET CAUGHT UP WITH WHAT IS BEING SHOWN ON A METER THAT A WELD CANNOT VIEW WHILE HE IS WELDING.
What you suggest has more relevance in a robot or automated weld situation. Regards Ed


txtReplyBody:
George for welds up to a 1/4 fillet the best weld will have no weave. For a 5/16 fillet a slight osscilation in the middle of the weld will push the fluid weld metal out to the sides in an even manner. Ed


txtReplyBody:
Typically increasing the voltage or trim in the spray or pulsed will eliminate weld spatter. Also with pulsed parameters increasing peak/backgound current or pulsed frequency/width opens up the arc length and reduces the pulsed drop size, (all this info in my MIG Robot Train book}It may be with the Power Wave that the pulsed inconsistency is the cause, i have witnessed this on other Power Wave installations. Try turning the pulsed off and set the spray weld parameters recommended in my book, you will likely find the settings produce faster robot speeds, the weld is more stable and you wont have to be a rocket scientist to figure out how to set arc length for spatter adjustments.


txtReplyBody:
Got the problem figured out, it was caused by inadequate grounding not the machine.


txtReplyBody:
Tom, be carefull of the 250 amp machines...we have a "Millermatic 250X" that we use for short circuit applications.  When we tried to use for spray transfer with 0.035" wire, it would overheat fairly quickly and shut itself off on thermal overload.  When selecting your new machine, remember to consider the required amp/duty cycle that the machine is rated for.  FYI, we use a Lincoln CV400 (3 phase, 400 amps @100% duty) machine for our 0.045" steel spray applications and for all flux cored applications, of course without any problems.  The industrial machines will have a high duty cycle which I believe you will appreciate if you want to get any production done...nothing worse than your high paid welders standing around waiting for the welder to cool off.


txtReplyBody:
If you look 4 inches to your left on this page at something called "steels and weld consumables" and visit "pipe" you would see the weld recommendations for 106 pipe. Consider an all position 045 E71T-1 gas shielded wire with argon 20-25 CO2, I prefer an Alloy rods products to Lincoln. Regards Ed


txtReplyBody:
The point is you dont. As with most weld shop  arguments "perception is rarely reality". With the argon oxygen mix your weld voltage is 2 to 4 less and the arc plasma is narrower, these factors  lead to finger weld penetration. Also the oxidation content of the oxy mix is twice that of the CO2 mix so your potential for weld porosity is much higher.
  To test the gas mixes, spray weld a 1/4 fillet first weld with the argon oxy, after the weld leave the wire feed settings then increase the voltage for the argon CO2 mix. Increase the weld volts till there is "no spatter" Cut the weld, polish the surface, apply a little acid and the result will speak for itself.


txtReplyBody:
Question [1]. In the various reading I do, I often find mixed messages and would like some clarification. Is spray arc less penetrating than globular, (I know you say to avoid globular) but its more penetrating than SMAW. (this info taken from a lincoln book) 
Answer [1] First the Lincoln book, most of the MIG data in the Lincoln black book has little to do with weld reality. Please note, the SMAW process with its low current density offers minimal side wall fusion on parts >1/8. MIG Spray transfer has much greater weld fusion potential than mig glob. Spray transfer welds with "higher weld parameters" than globular, and the spray provides weld stream rather than globular drops. The spray stream like a small stone dropped in water penetrates greater than a larger drop. 

Question [2]Is there a time when globular is worth the spatter? 
Answer [2]. Globular is practical on thin gage especially when welding "gaps and tubes". Harley BIKE frames and other tube application  are welded with glob transfer, most of thes welds are made "vert down", As the tubes offer a small weld surface and the welds are made vert down spatter tends to end up on the floor rather than on the part.

Question [3] In the books I read I often see short circuit referred to on 3/16" steel with voltage up to 22. I know in your book it says up to 1/8" and 20v. Is 1/8" truly the max for a single pass weld? 
 Answer [3] First short circuit is not attained with 22 volts the resulting weld transfer mode will be "globular".
If you want you can weld 3/8 steel with short circuit, the problem is the welds will have poor fusion and the weld deposition rates will be very low. As spray can be used with an 035 wire to weld >1/8 parts in the flat and horizontal positions, and the spray provides both higher weld deposition and greater weld fusion why would you use short circuit? 

Question [4]I have seen welders spray arc in vert. down position. Is this a red flag. Are they probably not getting penetration but just think they are? 
Answer [4] Spray is fine especially with an 035 wire for vert down welds on plates up to 3/16, using typical wire feed rates 500 - 600 ipm with 24 to 26 volts, over this thickness lack of weld fusion will occur.

txtReplySubject:
RE: clearing up some mixed messages from sources


txtReplyBody:
Ed, please explain to me the proper precedure for cutting a weld, polishing and what acid. I would like to try this in demo's. By the way, we finally got the supplier to get 85/15. I use it on our robot to compare gasses if the machine parameters are set right there is not much spatter difference than 92/8 with more penetration. I cant believe so many people are using 92/8.

txtReplySubject:
RE: Pros and cons of using 85%A-15%co2 compaired to 95%A-5%O


txtReplyBody:
Wow,
    once again I have learned alot! Especially about the spray in vert down. One question though,I am pretty sure, its been a while since I took my cwe/cwi test but D1.1 does not allow spray in vert position. I could very well be mistaken but if not, why would d1.1 not consider vert down spray to be a viable alternative. And thanks for your reply!


txtReplyBody:
Yes, I see your point. We use it more so that the other students who are not welding can see what varying stickout during  weld does to the voltage on the machine. A great teaching tool.


txtReplyBody:
Cut sample with saw, polish with grinder disc that will give shiny surface,  place a drop of nitric acid on the weld surface after reaction rinse test piece with water.  Remember the argon with 8 to 10 CO2, does PROVIDE LOWER ENERGY than 15 co2, however with many spray applications <1/4 it may be beneficial to have lower weld heat.


txtReplyBody:
The bottom line most weld code data on the subject of MIG has little to do with weld reality.


txtReplyBody:
The 250 amps can handle most alum applications, however for spray with an 045 carbon steel wire you need > 260 AMPS


txtReplyBody:
Thanks Ed.Lots of good info here.Gotta let my friends know.


txtReplyBody:
That makes sense.  But then why all the conflicting schools of though in regards to electrode manipulation, push/drag, et al?


txtReplyBody:
George when you read the information on this site, what is the primary message about the state of the weld industry you come away with? Answer this and that answers your question. Regards Ed


txtReplyBody:
Two points. [1] See the issues that can occur when you purchase a so called "intelligent Lincoln PowerWave MIG power source", as I have said many times its better to purchase a stupid MIG power source and provide it with intelligent instructions. 
[2] The MIG wire industry has a difficult time complying with the AWS wire manufacturing specs, so you should expect bull from their reps.


txtReplySubject:
RE: TIG - De-Oxidized copper tube to brass valve body


txtReplyBody:
Mike, you may want to look into brazing the joint.  I know Handy & Harman makes Ti brazing materials, but since you are above 800F, you will still have the same oxidation problems that you have with welding.  A couple of other good references are from "Timet" (Timet.com) and "The Titanium Information Group" (TWI.co.uk/  - I believe you can find it there).  Cleanliness and keeping oxygen away are the most inportant things to remember.

Steve


txtReplyBody:
Jaime, the bottom line is you can use either an 035 wire or 045. AS the weld has no need to be larger thyan 3/16 and the WELD IS AROUND A SMALL TUBE start out with regular spray transfer with the 035 wire set at 650 ipm 
(approx 10 lb/hr). Then swith to an 045 for comparison set this wire at 420 ipm which is 12 lb/hr, adjust the speed  and volts. Examine both welds and especially the effect of the weld on the tube. The best weld control will come from the 035 an ideal gas mix 8 - 10 co2. Regards Ed

txtReplySubject:
RE: Maximum amperage allowed in tube to flange application


txtReplyBody:
Sorry Mike not familer with this ESAB power source. Ed


txtReplyBody:
What root prep and gap did you provide? (optimum 1/16 land 3/32 gap). What size tungsten? (3/32 minimum). Did you try higher energy gas mixes like 
60-70 HELIUM bal argon, or argon with hydrogen? let me know the results Ed


txtReplyBody:
Don its all in the clock method. In this process parameter control method the focus is on wire feed rate anyway. If you set 16 to 20 volts you know you are in the short circuit wire feed range, if you set 25 to 30 volts you know you are in the spray wire feed range and settings as indicated in the clock settings for each wire diameter. Regards Ed


txtReplyBody:
5ft x 10ft sheets laid out in an area 30ft x 50ft, the joint is a square butt, without fixed backing. Trying to maintain planer flatness.
The welds have to be "leak free" from less than 1 inch of standing water. Have used back stepping manual welding and also a Bugo track welder to do this before. We use a Tig welder for tacking so we end up with a good consistent weld profile.
Full penetration welds are not nessesary. All of the above has resulted in "oil canning". Trying to eliminate as much as possible.


txtReplyBody:
yes, I see your point, was just trying to figure out some kind of way of figuring out amps. Not something I need for parameter issues I realize. One other question. We often get a weld face requirement other than slightly convex, ie.. flat or slightly concave. For these short circuit face issues we should set the correct volt range for the thickness (15-20v) then bring the ipm up to maximum short circuits per second for sligtly convex then reduce ipm to get flush then again to get slightly concave. Is this correct?


txtReplyBody:
Brad consider standing some of the sheets up with a clamping systems that holds the joint against a copper or alum back up bar (heat sink) and use the bug to weld "vert down" with an 035 wire. EC


txtReplyBody:
Thanks Ed, that is a simple way of controlling distortion, and it will work...Brad


txtReplyBody:
As many of thse products have really poor arc charateristics I doubt if you will see a measurable  difference. Keep in mind if you maintain a constant wire stick out there will be no difference with the CC/CV out put. Also I believe you can buy CV adaptors for CC equipment.


txtReplyBody:
To shape a weld you can adjust either the wire feed or voltage, EC


txtReplyBody:
Inductance only benefits short circuit, adding inductance (resistance) slows down the current surge that takes place each short circuit. Inductance is typically built into most good MIG equipment and therefore an inductance control is not necesary. If you have an inducatance control it often works best when set in the middle. Set your short circuit wire feed and volts, then have someone adjust the inductance control. Listen to the resulting arc sound. When the crackle sound is most rapid you have set the optimum inductance. If you want more wetting you would add inductance, if you wanted the weld to freeze faster you would decease inductance.


txtReplyBody:
Go with TIG, you have two things that MIG does not do well [1] thin gage [2] small weld lengths TIG will produce far superior welds. Ed

txtReplySubject:
RE: Welding 1/16-1/8 aluminum,  TIG or MIG?


txtReplyBody:
consider something like an "all position" E71T-8 A LINCOLN 203 M , IT HAS good low temp properties. Your concern may be its size, It may only be available in a 3/32. To weld gage a <1/16 is preferred. Lincoln or Alloy Rods will have the products you want. However when you see the smoke coming of these products you may live longer if you stay with the stick welding. Merry Xmas Ed


txtReplyBody:
That's a good point.  Thanks for the information Ed.  

Stephen


txtReplyBody:
Larry it makes no sense to use the tri mix gas for this application  and your weld settings also make no sense. Did you purchase my MIG train book all the weld data you need for carbon steel and stainless is in the book and you would not have to spend all day reinventing the welding wheel. Ed


txtReplyBody:
The main advantage I find to metal core wires as opposed to solid wires is ease of manufacture and availablilty.  140S-1 from ESAB costs about $26/lb, and I can find 140 tensile strength metal core wire for about $8/lb because it is easier to make due to how hard it is to draw 140S-1.  Also, it is easier to make odball chemistries with metal core wire as alloys can be added as powder instead of having to order a whole heat of special chemistry metal to draw down into wire.


txtReplyBody:
Put your focus on MIG current. A >250 AMP power source at 60 percent duty cycle wilh an 035 wire will meet your needs. Miller or Hobart there is little difference.

txtReplySubject:
RE: Hobart 175 or Millermatic 175? Which to buy?


txtReplyBody:
I have no exp with this equipment, however if I was to purchase I would select the Miller.


txtReplyBody:
Actually you are comparing a 1 phase welder to a 3 phase welder there.  Not really a fare shake...  The Miller equivalent to the Thermal Arc Predator, for 3 phase, is the Miller Trailblazer.  I own a one.  That is one awesome machine.  I chose the T-blazer over the Predator for a few reasons, the main one being in my area, Northwest, where I live practically everything I see on construction trucks, welding rigs, and maintenance trucks use Miller.  Some have Lincoln, and very few have a Thermal Arc.  The Trailblazer gives you remote capabilities where as the Thermal Arc, when I was shopping, did not have those options as of 2-3 years ago.  I also did not like the fact that it had aluminum windings instead of copper, which Miller uses.

If all you are going to use it for is stick welding and a backup generator, I would just get the Miller Bobcat 225.  If you want to get set up to tend to some aluminum and think you might get the TIG attachment, go for the Trailblazer.  It's more money but well worth it, and the remote foot feed is really handy.  I love mine, and the newer models keep getting better.  I just aquired a wire feed box and love that 3 phase welding output.  I also bought the TIG box, with high freq., I love that as well.  

Stephen


txtReplyBody:
The 175 Handler from Hobart requires 230 V input and provides 175 amps. As mentioned in previous questions these power sources for welding thicker than 080 are practical when the wire size is 030 As you MIG time is so low for the year I would tend to stay with stick or wait till you can purchase a larger amp power source 220 -250 AMPS.


txtReplyBody:
The help the first time was nice. To remember me and come back with more is even better. Thanks again, nice site, lots of info.
Have not decided what to do. Waiting for price on a used 220 amp and dropped an 80lb. piece of cast on my thumb saturday so I will be out of the shop for a week or more and this gives me more time to look around.

Thanks again, Lynn.


txtReplyBody:
The gas flow is the likely cause. The flow reading on your flowmeter may not be  relevant.  CHECK the gas flow rate as it exits the MIG gun nozzle Ideal flow 30 - 35 cuft/hr for carbon and stainless


txtReplyBody:
Thanks Paul there is a lot of people at Lincoln and Miller that would disagree, mind you they have not read it. Regards Ed


txtReplyBody:
JAMES go to the mig and flux cored section click on flux cored and pipe and self shielded data available at end of section. Regards Ed


txtReplyBody:
George if this is the first {hot pass] over the root please remember the rutile slag, E71T-1 is a "fast freeze" weld wire ideally suited for vert up, often poorly suited  for specific flat and horizontal welds. For these welds an E70T-1 wire with a basic, slower cooling  slag with increased deoxidizers is better suited. 
   The weld porosity is likely a result of the fast freeze weld characteristics which provide rapid weld solidification. The following will reduce the flux cored weld porosity.

[1] Increase your wire stick out 6mm and turn up your wire feed to the 2 oclock position {another 70 ipm} and give yourself an extra volt
[2] Use straight CO2 with higher voltage
[3] Use push technique but reduce angle,
[4] Slow down weld speed
[5] Minimize weave
By the way  my book does not recommend the drag  pull or backhand technique it recommends only the push or forhand technique only for controlled flux cored welds Regards Ed.
regards Ed

txtReplySubject:
RE: E71T-1 Flux Cored and  Weld Porosity


txtReplyBody:
check out the mig & flux core data area in this site; look under gasses for more information than you would expect to get

take the time to thoroughly peruse the entire site it will be well worth your investment

if you have the spare change invest in the training book it has more concise & helpful information than anything I have seen elsewhere for any amount of money 

good luck 
D

txtReplySubject:
RE: C02 vs CO2/ARGON as a MIG shield gas


txtReplyBody:
Use GTAW AC 3/32 pure tungsten. Regards Ed


txtReplyBody:
The best wire ever for welding on Galvanized steelplates is the Innershield wire from Lincoln.
Fillername: Innershield NR-211MP (E71T-11)
Wirediameter from 0,9mm to 2,0mm.
Suitable for platethickness from 1 - 12mm.
Depositrate from 0,9 to 4,2kg/hour. It`s not so productiv, but very good welding for Galvanized steelplates. You will still ned to "silverpaint" your weld, or use a cold galvanize spray paint.


If you need information about welding economy, please look into:
http://www.industri.no/e-weld/eng (You will find multi lingual software) and other stuff.


txtReplyBody:
No I dont think "much" about three part gas mixes for carbon steel MIG welds, I dont think  "anything" about these mixes as they are a complete waste of time and money. 
   In the thickness range you are in an ideal mix suited to both short circuit and spray for "manual" applications would be 20 % CO2. If most of the applications are welded with robots the increased wire feed (current) capability of the robots would benefit from a slightly lower energy mix like 15% CO2. Again this mix provides both short circuit and spray tranfer, however  with the higher robot weld current this mix will  lower the weld burn through potential in contrast to the 20% CO2.


txtReplyBody:
Mike.

  First for welding 3/8 your 035 wire feed setting at the 2 o'clock position (500 ipm) is low. You would typically use this setting to weld <3/16 applications. For 3/8 you would crank your wire feed wide open 5 o'clock  (at least 700) ipm.  Perhaps the reason you use the low setting is too minimize the weld spatter. As argon 20 CO2 should cost no more than argon 25 CO2 you can understand the cost consequences between a weld depositon rate of 7.7 and 11 lbs an hour. If you cannot change the gas try 1/2 volt reductions to bury the arc in the weld. Reducing the arc length slightly can get some of the droplets into the welds. However if the voltage is lowered too much the spatter condition will get worse. Regards ED


txtReplyBody:
Thanks, Ed. I increased the wirefeed to slightly beyond 3 o'clock, the power supply is a nominal 250 amps, although it seems to be capable of 300. I was able to get a fairly smooth arc after a splattery start at this setting. The local welding supplies do not routinely supply anything other than C25, if you can believe that. I have one that will do a custom mix but they are making a big deal of it.


txtReplyBody:
Mike if you get the opportunity, purchase one cyl of argon and one cheap cyl of CO2. Provide two flow meters, hook the two meters to a Y connector. Set the CO2 flow at 10 CF cuft/hr and then set the argon at 35 -40 cuft/hr, Reajust the CO2 till you are happy with your spray mix. This way you will save about 40% on your gas cost, and you can tell the weld distributor where to stick his big deal argon mix cylinder. Regards Ed


txtReplyBody:
Mike its linear, its also a high gear ratio feeder, there are a few out there. The vast majority of wire feeders,feed have a max feed  rate of 650 to 800 ipm. Regards Ed


txtReplyBody:
Thanks, the numbers are not all directly proportional to the wire speed, but that could be the way the dial was set up. In any case, I'm glad I took your advice re actually measuring the output when in doubt. I obtained some 92/8, and plan on adding a CO2 cylinder with the double regulator as you suggested to boost to 10 or 15% when needed.


txtReplyBody:
Yes, in pulse welding the wire feed rate is constant.

txtReplySubject:
RE: Pulsed deposition rate of 052 E70s-6 wire at 350 ipm


txtReplyBody:
If you are using DC- you should be using a self shielded flux cored wire and I hope you are using it outdoors, These wires WHICH DO NOT HAVE THE BENEFITS OF A SHIELDING GAS have arc stabiilizers  in the flux, Some self shielded wires work with DC+ others are more stable with  with DC-. For the 1/4 6 mm vert up fillet weld I use a slight oscillation in the center of the weld. The self shielded wires will give you inferior weld results in contrast to the gas shielded wires.  The inductance will not affect the open arc transfer (inductance is beneeficial for short circuit)however to improve the arc starts use the lowest inductance settings. Regards Ed


txtReplyBody:
More info - We are using .045 Hobart Fabshield 21B with 75/25 mix, on 3/8" steel vert up. Those are the spec we were given. Just trying to minimize undercut and get less convex face. Using slight oscillation, 15deg Angle, Setback 1/2", 20v, 150 ipm, low inductance. Suggestions?


txtReplyBody:
Don, If given the choice a Hobart all position flux cored wire would be my last choice.

When using a flux cored product I respect, like an Alloy Rod or Tri Mark I would set the weld voltage at 24 and the wire feed at 260 ipm for  start data. With an Alloy rod wire its easy to do your welds on 3/8 with the wire feed set at 350 - 400 ipm and 25 volts. With a quality product you can sometimes  double your weld (deposition rate) production each hour. The big thing with these wires is minimize the arc length with control of the vollltage. Use a 5/8 to 3/4 wire stick out. With the vert up welds, use a slight oscillation from the weld center. Don all this data and much more is in my MIG/FCAW book.


txtReplyBody:
Yes, i have your books and teach from them. This is for a contest and the consumables are chosen for us. how about the effects of angle on this weld?


txtReplyBody:
hold gun at about 60 to horizontal pointing up/
With the data I provided you should achieve a decent small drop spray Its important to use 23 to 25 volts with these wires to get this spray,Keep arc length at 040 to 060 . Best way to test if parameters are good. With the data provided, do a horizontal butt weld on 1/4 plate, if welld too hot lower wire feed at 3o ipm increments, and fine tune volts by examing the arc gap distance. Once this weld is set  vert up on 3/8 plate should be a breeze. If you are getting undercut its likely your weld weave is too exagerated, use a small oscillation in the weld center to let the weld flow out naturallt to the wall edges.


txtReplyBody:
Jim The first thing to remember about the primary difference between oxygen and CO2 is that one percent oxygen is approximately ten times more oxidizing than one percent CO2. The concern for CO2 with austenitic stainless is the possibility of carbon pickup from the gas to the weld. This is  important especially when Low carbon  grades of stainless are to be welded. As  CO2 is less oxidizing than oxygen this results in cleaner  spray transfer or pulsed transfer welds on parts over 1/8.  Parts thinner than 1/8 (3 mm) are influenced by the weld heat and typically will  have an oxide reaction with  atmospheric oxygen. 
To reduce the opportunity for carbon pick up, use a mix with less than 4% CO2 for MIG stainless. The 2 to 3% CO2 mix is ideal mix and will produce no more carbon than is found in a low carbon austenitic stainless SMA weld. With an industrial mix containing   less than 2% CO2 there would be a concern for the quality and consistency of the industrial cylinder  mix.  For weld gas data I suggest you visit the MIG gas section on my web site www.weldreality.com


txtReplyBody:
I am a little confused about the question are you looking for edge prep,weld process data or material data Regards ed


txtReplyBody:
Jim The first thing to remember about the primary difference between oxygen and CO2 is that one percent oxygen is approximately ten times more oxidizing than one percent CO2. 

The concern for CO2 with austenitic stainless is THEREFORE not oxidation its the possibility of carbon pickup from the gas to the weld. This concern is warranted especially when "Low Carbon" LC  grades of stainless are to be welded. 

As  CO2 is less oxidizing than oxygen this results in cleaner  spray transfer or pulsed transfer welds on parts over 1/8.  Parts thinner than 1/8 (3 mm) are influenced by the weld heat and typically will  have an oxide reaction with  atmospheric oxygen. 

To reduce the opportunity for carbon pick up use a mix with less than 4% CO2 for MIG stainless. The 2 to  three percent CO2 mix is ideal and will produce no more carbon than is found in a low carbon austenitic stainless SMA weld. With an industrial mix containing  less than 2% CO2 there would be a concern for the quality and consistency of the industrial cylinder  mix. tHIS MIX WORKS GREAT WITH BOTH MIG SPRAY and PULSED SPRAY WELDS.   ED


txtReplyBody:
Frank visit the steels and weld consumables part of my site and go to metals A - D. Ed


txtReplyBody:
I asked Ed the same question about a year ago. I got two flow meters and a y valve setup. I added an inline fuel filter like you would use on a gas engine down line from the y valve. I adjust the flow meters to get the mix and weld appearence I want. I save a bunch on gas and don't have as many bottles on the floor.


txtReplyBody:
I was recently in a manufacturing company that had a small welding department, and each welder had 2 bottles of gas, a c25 and a tri-mix. These were connected to a "y" with shutoff valves on each leg. I didn't ask detailed questions about the setup, but apparently the operator can switch between gases, or mix the two. They were using .o35 Lincoln wire (number?) and miller welders with the hand crank,and doing welds on .125 and .250 mild steel that were very neat, flat, and good looking-they looked like "tig" welds. Question, for Ed or anyone else, what gas mix do you suppose they were using; will tri mix and short circuit produce "pretty" welds that have a "tig" appearence? Just wondering, all my experience has been with c20 and c25 and I've never been able to duplicate welds with that appearance. Thanks for any comments.


txtReplyBody:
Visit t.he MIG and flux cored data and then take a trip in the weld gas section its all there


txtReplyBody:
Don there is no logic to using two cylinders when you can use one. However in this illogical industy people do it. Using two flow meter to a Y connection and you can set the flow rate ratio to make a spray mix from a cyl of argon and a cyl of CO2. However you will never know the composition and it will vary and you will pay the rent on two cylinders. You will know when the gas mix is less than 25% CO2 through the spray arc characteristics. The bottom line, the two cylinder do it your self gas mix simply  makes no sense, as a single cyl of 85 argon 15 co2 will weld all carbon steel and all gas shielded, all position flux cored applications.


txtReplyBody:
Jordan there is a table in the book that provides the data for the 0.100 materials. The weld data depending on gaps is typically wire feed 450 to 550 ipm, with 24 to 26 weld volts. Also start data is in book, however, to start this weld I would use the same wire feed as the weld and with one to three additional volts. At the weld end again use same wire feed as weld data with 2 to 4 volts less.  

For your gas gas if you use a mix with oxy in in contrast to CO2 you typically lower the volts one to two volts and vice a versa. If robot welds are on parts >0.100 your shop needs is argon 10 co2. Have you consisdered purchasing the video its all on there too. Ed


txtReplyBody:
Is my area unusual, in that two major welding suppliers consider 85/15 a custom mix? In fact, I had to contact the main branch in the next county to even get 92/8! And we're part of the metro NY area.
BTW, on my wire feeder, I discovered that somebody at the factory had reversed the bakelite gear on the drive with the steel gear on the output shaft, thus turning a 600 IPM feeder into an 1800 IPM feeder.


txtReplyBody:
It simply indicates MIG weld process ignorance. If you had dealt with this company  for decades this would not come as surprise.


txtReplyBody:
If you read this site and my books it should  not come as a surprise that many weld distributors are not aware of the real practical welding feature benefits of the gas mixes they sell. Educate them and good luck Ed.


txtReplyBody:
Both these welds are spray and using 035 Spray  paramaters (in books) you can produce the welds you describe with most common argon mixes except 75/25. To get the flat weld on the 1/8 set 500 -600 24 26 volts and make sure you weld faster than normal for the 1/4 weld 650 750 ipm 28 to 30 volts. They do not need the two mixes all will be attained from Argon 15 co2. Ed


txtReplyBody:
Hello all,
Just wanted to throw my two cents in.  I have a Panasonic robot with a 350RA source and use it only in the low pulse mode.  I'm welding parts .063" thick with 1.2mm 4043 wire and I have to state that the results are quite satisfactory.  After reserching a number of systems for this application I found this the best fit.  Cosmetics are important to the extent that customers without a great deal of welding experience "know what a good weld looks like" and the low pulse mode on thin aluminum gives them that along with a quality weld.  I would be interested in seeing your comments or suggestions regarding thin aluminum welding with pulsed MIG.


txtReplyBody:
Eric there is no justification for using a high energy helium tri mix for a low energy weld application like a MIG pipe root weld. The gas companies unfortunately are ignorant to this fact. 
As I have said many times you dont run a weld  shop based on weld sales advice. You can always order the argon CO2 mix from the speciality gas division. It will cost more, however once you establish its the mix to use you can then demonstrate it to the gas Phds and educate them on a practical gas mix. Of course if they made it they would then have to sell it at 50% less than the helium tri mix. The MIG mix CO2 content must be less than 5% to minimize the opportunity for
carbon pick up. For the short term try the argon 2 oxygen for the root short circuit welds, the energy levels are similer as the 2 to 4 co2. 

With stainless MIG root welds, due to excess shrinkage  you will have to try some root gap dimension variations, and there may be an issue for the overhead part of the root welds whatever the gas mix. 

Ref TIG try a 5/32 tungsten electrode with a 1/8 filler and weld the root at 200 to 250 Amps, you will be surprised how fast the the TIG root is complete, Regards Ed.

txtReplySubject:
RE: Tri Mix and MIG Stainless Pipe Welds


txtReplyBody:
if its 0.4 mm you are in trouble with MIG should be TIG. You can use the 309 however its likely not necessary Ssimply use the 625. Regards Ed


txtReplyBody:
As with many robot cells the gas at the regulator has little in common with the gas flowing out side the gun nozzle. Due to hose connections the gas flow restriction can be extensive  

First thing you should do is take the gas line and run it to a flow meter attached to the wire feed control on  the robot. If the wire feed control is outside the cell bring the flow meter to the nearest point to the robot. A good position would be by the robot cell door. The bottom line install the flowmeter as close to the gun as possible and get a gas flow monitoring devise to ensure that the fas flow from the gun nozzle  is 25 - 35 cuft an hour. Note at 30 cuft/hr from the gun the flowmeter may have to be set> 40 cuft/hr. What ever the flow tube reading is then stick a label and a pen mark on the flow meter so everyone is aware of the desired settings. By the way for those companies that use pressure instead of flow rates I would rather use flow its much more accurate. Regards ED.


txtReplyBody:
Ed,
Thank you for your good advice. I will do what you have suggested.
Thanks,
Manzor


txtReplyBody:
Ed, how is there a loss of CFM between the meter and the gun? Are we talking about leaks? Otherwise flow would be constant at every point in the line, pressure would vary?


txtReplyBody:
Its usually the brass hose gas connection fittings which have too small an orifce. Remember possibly 90% of the robots installed in the US did not have a gas flow calibration check before they were shipped to the customer. Regards Ed


txtReplyBody:
TRY AN 035 S3 L50 WIRE LOWER SILICON LESS WETTING LESS BURNTHROUGH, CHANGE GAS TO AN ARGON 5 OXYGEN SETT THE WIRE FEED AT START 500 -550 IPM MAKE SURE THE ACTUAL VOLTS ARE 24 -26 AND USE A SLIGHT WEAVE. SORRY FOR DELAY ON RD. ED


txtReplyBody:
Sorry for delay I was on the rd.

typically best process TIG, AZ618  thicker components are pre heated 300 to 500 f. i DONT KNOW IF ITS NECESSARY TO PRE HEAT THE THIN WALL TUBE Regards Ed


txtReplyBody:
In regards to your gas search MG Industries ( MESSER) has your gas requirements as a standard item. Ask for 205 which is Argon/ Co2 5% balance.


txtReplyBody:
When you have a valid weld application please call Mr Zugelder 765 455 0853.


txtReplyBody:
thanks ed, will give him a call
                           doug


txtReplyBody:
Not if you use the high end of short circuit or spray. Ed


txtReplySubject:
RE: Anybody thinking of buying a pulse welder?


txtReplyBody:
Think og metal cored for carbon steels as a mig wire with a little iron powder in the middle. metal cored wires work well the bottom line is they are not needed for carbon steel applications. These wires do however provide advantages for low alloy steel applications. No advantage from copper coated MIG wire versus bare coated Its all in the mind of the salesman. Regards Ed.


txtReplyBody:
Your gas is fine, increase your MIG gun lead angle, this improves the cleaning action. What is your weld data wire feed, volts weld size? What is your wire? Ed


txtReplyBody:
John the Management book is 600 plus pages, apart from MIG and flux cored it deals with pipe welding and with the requirements for robot weld process controls. The new training book is designed as a self teaching MIG process control book with 160 pages and 160 questions. The video has been improved and  with a robot process control addition. Regards Ed.


txtReplyBody:
John,
I too purchased the book and video set a long time ago.  Since, I have purchased the Mig Welding (600 pgs) book it has quickly become my most referenced text.  About 2 yrs ago I began using the Training book for my welder training.  I upgraded at thet time, to the new video and found it to be well worth the upgrade.
Just a user puttin' their 2 cents worth in.
PWC


txtReplyBody:
FULL PRESSURE is to FULL CAPACITY as DIMINISHED
PRESSURE is to DIMINISHED CAPACITY.

For your case:

2600 psig is to 335 scf as 495 psig is to X scf.

Multiply the end numbers and get 2600X.

Multiply the interior numbers and get 165,825

Divide 165,825 by 2600 and get 63.78

Answer: X = 63.78 scf of gas remaining when the  pressure is 495 psig.


txtReplyBody:
When welding carbon steels, once you use a two component argon mix, you will find there is no "significant weld speed differences", (wire feed per application potential), found between a two component argon – oxy / CO2 mix or a three component mix containing argon – helium - CO2/oxy. Extending the wire stick out will have a greater impact on wire feed rate potential (weld speed) than a change from a two component to a three-part gas mix. The primary weld changes you will note in your MIG gas research project will be in the:

[a] Transition current attained between short circuit and spray transfer.
[b] The required weld voltage which will affect the arc plasma intensity and plasma  configuration.
[c] The weld energy attained. 

By the way your selection of a 1/16 butt weld application will greatly limit your test. For your  thin gage, low current short circuit application, you will require restricted low wire feed rates with an  0.035 MIG wire. The best weld speed test for a MIG gas, use the spray transfer mode with a 0.045 wire. Produce a 3/16-fillet weld, which allows for high weld speeds. Use an automated weld carriage to reach and record the maximum weld speed potential. My 600 page Management Engineers book on MIG welding has over 150 pages on MIG gases  and high speed welding, ask your librarian why its not in your school library. Regards ED


txtReplyBody:
Sorry Paul I was tired when I replied to your question. The bottom line of course when you cut down on the gas surge you save a little gas however when a cylinder lasts foe more than 10 hours of arc on time, its a real low cost bargain. I would like to see your expertise and energy applied to real weld cost reduction, thats attained from attaining optimum weld production and quality. Regards Ed


txtReplyBody:
First ensure the grounded fixture (could be clamp) has a cable to a copper ground rod embedded at least three feet into the floor. All three ground cables can be attached to the same ground lug on the part, clamp or fixture sitioner. Regards Ed

txtReplySubject:
RE: Fixtureless welding of part by 3 Mig Robots


txtReplyBody:
Does it not matter if they are all welding at the same time? So, is the first welder going to receive current feedback from the second welders cct.?


txtReplyBody:
If they are traditional CV equipment the answer is no if they have a voltage feed back sensor, they will be confused, thats another reason to avoid useless bells and whistles. Ed


txtReplyBody:
I often wondered why welding gasses were not measured like refrigerant... by weight. I guess there is little chance of dealing with a liquified material in the tank? (uncompensated for by your formula) 

Sorry, if my comment serves to cloud rather than define and I suppose the gas data section here would establish or eliminate my suspicion... but this serves as proof of the danger of a little knowlege. 

Also, can dissolved components of a gas mix condense (or precipitate?)out as a liquid component at some point in a pressurized container, and if so, what kind of pressures are required and what would be nte names of these thresholds?
Thanks 
D


txtReplyBody:
spray should be used in the FLAT, HORIZONTAL POSITIONS (ALL THICKNESS) AND VERT DOWN ON PARTS WITH A THICKNESS <3/16


txtReplyBody:
Not just horizontal fillet but all horizontal joints can be spray arc welded correct?


txtReplyBody:
all horizontal welds can be spray weld as long as the metal thickness can support the weld heat


txtReplyBody:
my choice would be a LINCOLN OR MILLER ed


txtReplyBody:
Mulling over a formula given to the guy with the gauges (I dont think it will be accurate; one side of his equation is liquid the other is gas) I was trying to verify terminology in your gas section without looking it up elsewhere; it was a stupid question...  but it might be beneficial to include a simple glossary around there somewhere if you run out of real things to do.
Regards
D


txtReplyBody:
d its not a stupid question its simply one I have no interest in Regards Ed


txtReplyBody:
Ignore the wire manufactures recommendations and use the lowest possible wire feed and volt settings. You will see a reduction in cracks. However this Ni Cr Mo wire will result in some cracks irrespective of what you do. Look at it this way, you attain much higher weld deposition rates with this process than with SMAW or TIG, so reap the benefits, bring out the dye pen and good luck. Ed


txtReplyBody:
Good question MIKE. 
With most weld applications the primary concern with heat treat is with the carbon or alloy levels. Of course the steel manufacturers and codes will all will have an input into required heat treat. For many carbon steels and low alloy steels multipass welds the preheat can be eliminated if the steel is dry and at the indoor temp. Caterpillar is one company that does not use pre heat on many multi-pass weld applications that typically require preheat. However interpass temp control is another issue. 

With many multipass welds you could elimiante pre heat as the first weld pass could be considered preheat, and the second pass will temper the first pass, again I repeat on these applications you should not ignore the interpass temp which is usually the same as the preheat temp. Ed


txtReplyBody:
You are maxed out a change to 052 will simply increase your weld burn through potential.

txtReplySubject:
RE: 0.052 Wire dia on parts 3/16 to 1/2 in. in thickness


txtReplyBody:
Carl all this info is in my books, yes there is a fixed rate of speed which is based on the maximum controlled weld deposition rate. 10 TO 13 IPM. Ed


txtReplyBody:
We have the guys from Cloos coming in today to talk about retrofitting these Motomans with a twin wire set-up.  Is this application worth looking into a twin set-up to increase deposition?

The questions never end...
PWC


txtReplyBody:
First tell me what they say they can attain for you then tell me how much it wil cost, in the short term be wary. Ed


txtReplyBody:
If the gas is mixed it wont seperate, unfortunately its commom to find two part argon CO2 mixes which are not mixed correctly and you will end up pulling straight CO2 from the bottom of the cylinder


txtReplyBody:
I use .052 wire, 98Ar 2Oxy gas, on parts as thin as 1/8" using spray arc. Works great, hardly any spatter. Its also cheaper.


txtReplyBody:
Good Question. With a robot you will have the opportunity to place delay times at the arc starts and weld ends. At the weld start the delay time holds the robot in place while the weld start data is applied, this time provides two benefits, [1] time for arc ignition and time for weld start fusion to occur. If the time is too long at the start, wire burn back can occur and the weld will have too much weld in the first 6 mm

At the end of the robot weld the weld /end delay is time for the crater fill, small fillet welds <3/16 dont need this time, the bigger the weld the longer the time. Alum needs more crater fill time than steel. For all MIG Wire burn back time should be set so that the MIG wire rises 1/8 to 3/16 out of the weld at the weld completion. This data is in my MIG train book. Ed


txtReplyBody:
Ni Cu wires and argon are used however with an alum bronze filler wire you could weld just about anything to that monel tank. Ed


txtReplyBody:
Thanks, Ed.  The info is much appreciated.


txtReplyBody:
thanks ed there are a lot of red faced engineers around my plant today when i changed some delay times and got a machine that was arcing out 17 times in a shift to only arc out once :P Do you still offer weld training if so is it available on weekends?


txtReplyBody:
You first check the wire feed rate, a monitor is available from Lincoln, check it as it exits the drum. Then check the amps or voltage in the pendant with that on the meters on the power source. Then check the gas flow as it exits the MIG gun nozzle. When you find issues and you will, have the robot company come in at their expense and calibrate the robot cells in the way they should have been done before it they were delivered to you. Ed


txtReplyBody:
thanks ed the robot company is at our site as part of their contract and have been there for weeks (finally installing password protection on the teach pendants after me chasing ppl for months) as part of qs900 should these robots be calibrated on a regular basis?

Also i noticed in your delay time post that you gave anne a number to contact you are you available to train again and end my suffering :)


txtReplyBody:
I'd second Ed's recommendation...we have a couple of their inverter TIG units, and one is not behaving well.  The unit trips the circuit breaker multiple times on its first daily start up; we've changed circuits, circuit breakers and even thrown a Fluke meter that captures the max amp load to no avail.  The only local, "authorized", repair guy said to increase my circuit breaker size to keep this from happening.  Thermal Arc said to send it in..."it's probably the main circuit board".  Of course this happened shortly after the ONE year warranty ran out.  We have put this unit on the back burner, and have since purchased a Miller inverter TIG unit, and didn't even consider Thermal Arc for our MIG machine (Lincoln on that one).  I believe that both Lincoln and Miller offer a three year warranty on all of their machines, and have and extensive distribution and repair network...stick with either in my opinion.

steve


txtReplyBody:
Calibrate once a year, check the wire feed rate and voltage anytime weld issues occur. My contact number  training  910 313 2940


txtReplyBody:
You know my thoughts on the Power Wave, this problem you have seems to be a feature of the Power Wave, If your manager had invested his "time" in visiting my site he would not be having robot or Lincoln equipment issues. Leave me a phone num and I will call you to ensure your data is optimum. May the power be with you Ed


txtReplyBody:
it is the data i fixed one machine yesterday by ensuring that all the weld schedules were averaging 24v or above after that the arc fails went down to a minimum. just to confirm though the data for pulsed spray should be 24v 180 amps min? Was trying to get info from the lincon rep yesterday and he only said anything above 400 ips feed speed should be pulsed :( (damn salesmen)


txtReplyBody:
damn i give up ed!!! I go in today and the project engineer has changed my data back to it's original values and gee they got alot of arc failures on it imagine that. So i guess for now i'll just try not to let these consistant arc failures bother me and let him out to hang. Not much else i can do. But I will keep a copy of some of your web pages with me and if the plant manager asks me why its arcing out i'll give him the story about you doing the consulting for the plant who wouldent listen and closed. Using the same lincon pusled welders well diffrent model probably. What do they teach in welding engineering to be stubborn and avoid doing anything that works. You should open a training school and see how sought after the graduates are. Maybe that would bring the welding world to reality.


txtReplyBody:
Joe if you rely on pre-scheduled pulsed programs you may well get yourself into pipe fusion issues. With pulsed you have to know which are the logical pulsed parameters to adjust to increase or decrease fusion. My MIG process control training book will get you on your way, and I am sure you may pick up a few MIG pointers from it that you were not aware of. 

No two pulse machines from different manufactures are the same, and pulsed powers sources that are the same model may have extensive electronic revisions if they have been purcahsed a few months apart. The bottom line the pulsed power source you qualify your weld on may be different than the one you actually weld on. Welcome to the ridiculous world of pulsed MIG. Regards Ed


txtReplyBody:
Jeff there are a few schools however will one be near where you live? Jeff use the school as a place where you can get your hands on the MIG and FCAW equipment and consumable, then apply the process control which you will learn in the books I provide. Ed


txtReplyBody:
Thanks for the advice. The next unit will definitely be a Miller.


txtReplyBody:
The bottom line, argon helium mixes without nitrogen have for decades met the highest alum weld quality requirements, on space shuttles to ships. A small amount of nitrogen when added to argon helium may add to the weld penetration depth or slightly reduce porosity, however increasing weld current, decreasing weld voltage, changing the gun angle, increasing the gas flow rate or changing the wire stick out will also have a similar effect. If it smells like gas marketing snake oil, it usually is. Go to the MIG section and check out MIG gases for more data. Ed.


txtReplyBody:
go to the steels section click on stainless and scroll to 303. Ed


txtReplyBody:
when I dont know I recommend alum bronze Ed

txtReplySubject:
RE: welding Tri Braze material and 2205 Duplex Stainless Steel


txtReplyBody:
Frank this application is not an issue if you use sufficient weld tacks and control your weld gaps. Weld vert down, short circ, 035 wire and for low short circ voltage use argon 2 oxygen. Your welders lack confidence because they lack weld process expertise. Invest a little money in them and provide them with my MIG Process training book. Ed


txtReplyBody:
Eric the issue is not the wire. howevever it maks more sense to use an e70s-3 wire on coated applications. You should be using argon 25 co2 with an 035 wire. Check the gas flow rate as it exits the welders guns, it should be 25 to 35 cuft/hr. Check that the welds are not too concave or too thin, check thta the welders are not using a long wire stick out 3/4 to an inch is norm on thin gage. If still having problems call 910 313 2940, this subject is covered in my MIG train book
Ed


txtReplyBody:
0.035 gas shieded E71T-1 FLUX CORED WITH 75 ARGON 25 CO2 GOOD LUCK AND KEEP THE WATER OUT

txtReplySubject:
RE: Steel hulled yacht .. which mig process?


txtReplyBody:
Rock your weld data is so far from real it can only be called fiction. Also do not expect to get consistent, small length aluminum welds from the ABB arcitec. ABB may make the best robot equipment in North America however that Arcitec power source has many issues and is a poor choice for your application. The Arcitec does not have the ability to provide consistent weld start, weld and weld end data for small aluminum welds. As you have so many issues I suggest you read a book on weld data and read more of the alum data found on this site. EC


txtReplyBody:
On this gage thickness,if set correctly, and pre-qualified, the spray transfe results with an 035 wire in the vertical down position will be as good as that attained with spray transfer in the flat or horizontal positions.


txtReplyBody:
Don few manual weld applications benefit from power source electronics, think about it all you you need is current at the tip of the tungsten. For variable control of the welding current, a current foot control is a practical option. Also the ability to switch the HF on and off and a switch from AC to DC and you can weld anything. From my perspective I believe that if the Linde product is is good condition it will likely be superior in its construction, potentail durability and ease of repair. Regards Ed

txtReplySubject:
RE: Do I need bells and whistles on TIG equipment?


txtReplyBody:
Todd congradulations on your passage to welding manhood.
With the MIller and Lincoln unit there is little difference in performance. My preference would be Miller. I would check the output WELD current of both power sources  at 10 or 20% duty cycle. My MIG train book will make you a master of your domain and also a master of your MIG equipment Good luck Ed.


txtReplyBody:
You have to have two cylinders for MIG welding both steels and stainless so why not have an argon 20 CO2 cyl, and a cylinder of straight argon. At the end of the day you will still pay the same without the gas mixing inconsistency. Regards Ed


txtReplyBody:
Bill,
 Ed's book, as an educational tool, would profit from answers to the questions he provides at the end of the chapters. Go back and check it out again; your presumptions were correct. All you need is faith. 

 The 25%CO2 is keeping you out of a stable spray transfer. Use at least 5% more Ar it makes a difference. It's in the book, but my supplier was very cooperative and I tried many mixes...
 ...I prefer 85%Ar/15%CO2 with similar size (?) Miller 250x. The globular to spray transition is closer to 190 than 210 amps and gives a better profile with more fluid -S6; the wires we can get easily. I guess I can short arc but only use it for spray and in in similar application or thinner 

Everybody seems to explain the transfer you experienced as something different, but the similar arc I got with Ar/25CO2 was blowing all over and could not be used for any practical purpose albeit deep, fluid, and spatter free. We wound up calling it [Twilight]Zone transfer and also found the digital display on the welder was functionally several volts off. I dont care what it was- it was of no practical value except to identify the BS artists at several different supply houses and to help me find a good rep. 

Change your gas mix

Gluck
John


txtReplyBody:
the gas mixer is calibrated at 5 cf min or 300 cf /hr keep this in mind when you set your MIG weld at 30 to 40 cuft / hr Not familier with the new  Lincoln power source at this time Regard Ed. By the way I dont believe in gas mixes unless they are attached to a bulk gas delivery system Ed


txtReplyBody:
with an 035 wire and 75 25 CO2 you do not get optimum spray, its spray plus globular transfer. You need a mix with <20 CO2 and yes this is a spray application.


txtReplyBody:
oh,oh, my mistake Ed, on the cfm its cfh,do they make flow gauges that go as low as .5 cfh? i want to use mixers because of my remote location and limited gas sevice.


txtReplyBody:
if these are self shielded wires I would recommend that the welders ues fresh air respiratotrs The best way to weld this stuff is with a robot it is unnafected by the the galvanized and flux cored fume combination.

txtReplySubject:
RE: Operator safety issues galvanized and flux-cored wire


txtReplyBody:
Mike I have never heard the spray weld surface ref to a stack of dimes. The ideal spray fillet weld made on cold rolled will have a flat weld surface. The weld will have minimal freeze lines. The outside edges of the weld will be straight, no scalloped or pie shapes. The weld weld may have a straight freeze line, solidification line, in the weld center. On welds <1/14 the welder will not use any weave or whipping action.  MIG spray welds can have an ideal weld appearence however the weld fusion may or may not be acceptable, this is the reason we should qualify welds (etch macro) before we provide data to shop floor personel.


txtReplyBody:
Sounds like the welders are applying their 6010 whip to their Mig welding.  I've been trying to break our welders of this old habit for years.  Hard to do in a culture made up of old welders (supervisors, mfg. eng, quality techs).


txtReplyBody:
To get the distinct "bike pulsed look". With your AC pulsed power source and a rounded pure tungsten tip you will use a "low current" setting. The current will be just enough to melt the filler wire. 

  You will provide the "lowest possible pulse frequency". Remember that adding to pulse width or pulsed time also reduces the amount of pulses per second. The low current and low pulse makes it easy to get the distinct pulsed appearence for alum or steel welds. The fast freeze pulsed welds reduce weld burn through potential. These welds do look great, however they also frequently create borderline weld fusion. 
 Ed


txtReplyBody:
I FOYU ARE GOING TO WELD STEEL THE LINCOLN WILL BE FINE, YOU CAN USE IT WITH EITHER FLUX CORE OR SOLID WIRE. TWO THINGS I DO NOT KNOW HOW THIS WOULD WELD ALUMINUM AS I HAVE NEVER TRIED IT, ALSO MAKE SURE THAT THE OUTLET YOU PLUG THAT WELDER IN TO IS RATED FOR THE LOAD THAT UNID REQUIRES. MOST PEOPLE ON THIS SITE WILL TELL YOU THAT THAT MACHINE IS A TOY. IT MAY BE COMPARED TO INDUSRTILA WELDERS BUT THEY WELD LIGHT WORK JUST FINE. MINE DOES!

txtReplySubject:
RE: Request for recommendation for beginner's equipment


txtReplyBody:
I suspect you will get more use out of the generator


txtReplyBody:
Fancy meeting you here.  
The change over isn't a complete guessing game.  Because we can calculate deposition rate we're able to calculate the reduction in travel speed for a given weld. We'll change the weld data to the new numbers and we should be pretty close.  
Example:
0.045 dia wire your running at 450 ipm will have a deposition rate of about 12.2 lbs/hr.
0.035 dia wire running at 650 ipm will have a deposition rate of about 11.1 lbs/hr.
That's a diff. of about 10%
That means you'll need to reduce travel speed by 10% for a given weld and you should be pretty close.
I'm serious... it's that simple.
I'll send you a conversion chart if you'd like. Give me a call... life doesn't have to be so difficult.
I'm glad to see your going to the right web sites for your welding advice...
Now quit messing around on the internet during work hours!
PWC

ps
how's the fishing this summer?

pss
Sorry Ed.  The last thing you need on your bulliten board is co-workers using it as a chat room.
PWC

gotta' go... here comes the boss.


txtReplyBody:
I'm picking up my new Miller Millermatic 251 Mig welder tomorrow night. I'm really looking forward to finally having a powerful machine after owning two small 100 amp "toys". lol.

Thanks again
Todd G
http://www.malibumotorsports.cjb.net


txtReplyBody:
this whole site and my books are dedicated to the subject all you have to do is "read" Ed


txtReplyBody:
CHECK THAT WIRE TENSION, SET THAT GAS, REMEMBER THE CLOCK SETTINGS AND BREATH THAT SMOKE. ENJOY ed


txtReplyBody:
It was likely made at the ESAB plant Florence SC


txtReplyBody:
I am the other half of this "discussion". You seem to have been placed in the middle. 

For the past 2 years I have been trying to learn the technical aspects of wire feed. Yes, I have purchased one you books. I am a retired ASME pipe welder, and fit your discription of a welder relying totally on skills. Somehow I've managed to blunder my way through around 60 ASME carbon and SS 6-G tests. I realize the need for a technical understanding of the wire feed processes. 

This discussion started on a different forum when another person asked why the manual for his 80amp Craftsman wirefeed stated that self shielding flux core provided better penetration than GMAW. The answer was that the reduced volume of the flux core wire caused an increased "current density". I do not think this is right? First of all, I don't think that little machine has enough power to penetrate anything, no matter what you run through it. Some aspects of CV were difficult for me to understand completely, but it seems to me, in the context of an 80amp machine with limited voltage, reducing the wire volume would reduce the amperage? If you max out the volts on that little machine (and tune the wire speed)FCAW-S has to be running at lower amps than solid wire? I beleive the reason that FCAW-S works at all with those little machines is because of the EN polarity, not current density? I also differentiate between penetration and weld fusion? I think the EN polarity allows the filler metal to fuse at lower amps, but will not provide penetration because EN requires a faster travel speed? (The effect of polarity is what I am personally interested in at the moment). 

I looked up the parameters for high end short circuit, transitional spray, and flux core gas shielded. I think the term "current density" is misleading, but understand that at the same amperage flux core will produce more energy. With self shielding flux core, though, I beleive it is a polarity issue? 

Can you tell I have too much time on my hands.


txtReplyBody:
Ed...ESAB has turned over service and repair of Union Carbide machines to Arc Products in San Diego CA (619)628-1022. The input current on the machine in question is 53 Amps and they do offer a service manual #12-392B, however replacement parts are limited.


txtReplyBody:
With this thin gage thickness, weld penetration should never be an issue even on gage stainless.  I hope you are using an 035 wire. Focus on the gun positions. Ensure the gun is directed at the part that needs the improvement in weld penetration. 
  As you rotate the part, rather than set the gun at the  10 o'clock position reset the gun at the 11 oclock position. Remember the more pronounced the gun push angle the less weld penetration, so a change here will make a difference. Also check your wire stickout, you can always reduce the stick out which again will add weld energy.  Good Luck Tom hope you enjoy the book.


txtReplyBody:
Ed, I believe what you are looking for is Lincoln Electric's Shield Arc HYP (AWS E7010-G)or Shield Arc HYP+ (AWS E7010-P1). More info can be found in Lincolns stick electrode guide on their website page 34 and 35.               http://content.lincolnelectric.com/pdfs/products/literature/c210.pdf


txtReplyBody:
When reading your question I can see you have already answered it. The issue is obviously the quality and consistency of the stainless welding wire. The Midalloy wire sounds like it has inconsitent chemistry. 
  I dont believe the Midalloy wire is the same wire as the Sanvik. I also believe your salesman is making statements about welding wires and he is simply not qualified to make those statements. Also why are you paying a premium for the stainless tri-mix , its a gas mix which requires higher voltage than the mix I recommend a gas mix that added to your problem. Ed

txtReplySubject:
RE: Stainless weld inconsistency, is it the MIG wire?


txtReplyBody:
Ed,

This is curiosity question on my part. That tri-mix gas referred to, I really detest that it is still being sold and marketed. It has caused major problems in my work life. In most situations 98%Argon 2%CO2 works very well for 300 series stainless.
Does that Praxair trimix nightmare have a place in welding application? 
Thanks for any input, Brad


txtReplyBody:
Short and to the point No, if you need more weld energy pulsed MIG and spray transfer will do the job with the argon CO2


txtReplyBody:
go to steels and consumables and click on aluminum,

txtReplySubject:
RE: Ed where on your site is the info on MIG alum welds?


txtReplyBody:
The weld sounds great I am glad to see the weld data and speed you set. Your start data is globular influenced by the start volts. Remember that a voltage that is good for a weld is not necessary good for a stationary weld at the start. Try both of the foolowing.
[1] Start your weld with optimum short circuit data 280 ipm 17 actual volts.
[2] Add three volts to your existing volts and finish the weld with the short circuit weld data provided. Let me know how you are doing and ignore the idiots. Ed

txtReplySubject:
REPLY on perfect  MIG weld without weld spatter


txtReplyBody:
The bottom line if you are looking to weld MIG short circ / spray and all position FCAW, any mix in the range of argon with 15 to 20 CO2 will provide optimum weld results. If your gas supplier does not have a mix in this range they should not be in the gas buisness. If you have not been to the MIG gas section in my site its worth a visit. Go to MIG and Flux Core Data.


txtReplyBody:
Been on the road, sorry it took me so long to view your response. Thank you! I agree 100%.


txtReplyBody:
Dear Ed, We are doing robotic seam welding of approximately one feet in length. Sometimes we get a very little porous hole at the start of the weld, which you can't see from the outside. But if you remove some portion of the weld, it becomes visible. 

Manzoor. Incease your arc start time and your preflow gas time, also you may be getting a gas surge or insufficient gas at the arc start. Check the gas flow rate at the weld start time. 


I have another type of problem. Occassionally, my weld looks snaky, i.e., it is not straight but bends in the middle portion of the weld. If I reduce the welding speed and adjust the voltage and wire feed, the problem goes away. 
I think it might be a arc blow problem. Could you give me some advise why i am getting this? Here are my welding parameters: Voltage 25-26, Wire feed 230 to 250 ipm, welding speed 35 ipm. Wire size 052. Pulse transfer mode. base metal low carbon steel with 1/8 inch thick. Do appreciate your feed back. Thanks, Manzoor

Manzoor if you read my books you would know your MIG wire size is to large, therefore you have to use unstable low parameters that do not provide spray transfer.
 ED


txtReplyBody:
Its called current density. An 045 fcaw wire has 15 to 20% none conductive flux whicg ends up as slag. If you put 200 amps through an 045 fcaw wire and 200 amps through a solid, 045  mig wire you get more energy from the fcaw wire as its a smaller conductor.


txtReplyBody:
ed thanks I think you will gain a few readers from settling this argument
regards
d


txtReplyBody:
Has it not occured to you, that after 40 years of use I would have the right answer to a fundamental welding question. Straight polarity puts the electrons, ie weld heat into the part which dissipates and spreads out the affect of the weld heat, therefore straight polarity provides minimal weld fusion. 
  When you purchase these low amp toys you have to use small diameter wires to get heat into the consumable. Instead of using larger SMAW electrodes the power source manufacturer is telling you you will get more energy from the smaller diameter self shielded fcaw electrodes.


txtReplyBody:
On page 76, Fig. 29 of your GAS METAL ARC & FLUX CORED WELDING PARAMETERS, the GMAW Short Circuit Transfer diagrams indicate that at 17 volts, 210 ipm .035" wire will run at 140 amps and .030" wire will run at 110 amps. Does this not indicate that a CV power source provides the current necessary to burn off the wire? Are you saying that .030(110amps) has more energy, will fuse better, and penetrate deeper than .035(140amps)?


txtReplyBody:
A 100 amps with an 135 wire has less heat than 100 amps with an 030 wire.The reason they promote the small daimeter self shielding flux cored wires for low current weld equipment is that the current density is such that a 100 amps on an 045 self shielded wire puts out more energy than a 100 amps on a solid wire.

txtReplySubject:
Current density and an undersize power source


txtReplyBody:
Steve the reason you never found a logical reason for the argon hydrogen / helium mixes, for your GTAW applicationsis there isnt one. 

As you know argon is inert, as a TIG gas it provides all the benefits you need. As you weld on small thin parts the additional energy attributes from the hydrogen and helium likey provide you with heat you can do without. As to the cleaning action of hydrogen, on the parts you weld I am sure the parts are super clean. The bottom line is if there were ten different gas mixes available for TIG welding I am sure your company would have all ten. If your welds are set correctly Argon does the job. For purge gases the fact that helium molecules are smaller than argon and lighter, helium could provide benefits for specific purge applications.

txtReplySubject:
RE: Argon helium/ hydrogen  gas mixes for TIG stainless and Inconel?


txtReplyBody:
With clean aluminum you still have a tenacious alum oxide surface protecting the aluminum. The weld data and technique you utilize will affect the removal of that oxide during the weld.
You are no doubt aware that the fore hand or push technique places the arc in front of the weld. The argon molecules and arc plasma then bombard the alum surface, breaking up the oxides so they dont become part of the weld. 
   Another important contribution to the oxide removal is the intensity of the arc plasma. A high weld voltage, (long arc length results in a low intensity plasma)  Using a shorter arc length (lower the voltage) actualy intensifies the arc pasma, improving the cleaning action. When you look at the MIG arc plasma, compare it to a flash light. Raise the flash light and the diameter of the beam becomes wider and less intense. Lower the flash light (LOWER VOLTS) and the diameter of the beam becomes narrower and the light more intense.
  So focus on your technique and weld voltage. Good luck ed.


txtReplyBody:
This is a difficult question as so many factors that influence the amount and intensity of the magnetic field have to be considered. The real issue would be to find equipment that can provide protection from a magnetic field.

txtReplySubject:
RE: Reed Switches in a Mig Welding enviroment


txtReplyBody:
I have seen the reed switches work very well on weld fixtures, and have also seen some big failures. The biggest thing to watch for is ground path for the welding current. The ground cable needs to run right to the part being welded. (attached to a part support block or a grounding button) If the current has a long path through a steel structure to get to the ground cable, it could magnetize the steel, causing a lot of problems with the reed switches. Good luck.


txtReplyBody:
Todd how is your new Miller? making smoke I hope.


txtReplyBody:
It may surprise you that, argon hydrogen, the gas that provides much higher weld energy than argon actually works best on many low current applications (<20 amps.) The reason is, hydrogen provides an oxide reaction with the weld surface, and the hydrogen puts more energy in the weld plasma. Both these features enhance electron transfer and therefore enable lower weld current to be utilized. EC


txtReplyBody:
Lets see, the Invision cost around $4500 and the CP 302 cost around $2300. I know that with the CP I can produce the highest MIG weld quality required for flat and horizontal welds. If welding out of position I would use flux cored with the CP. So at the end of the day, the CP 302 will cost 50% less, its likely more durable, EASIER TO OPERATE  and easier to repair, I believe I would recommend the Miller CP 302. As for the sales rep advice, give him a break. After all if you were a salesrep and you got commision on a sale of $27,000 worth of MIG equipment versus versus $13,000. What would you push. Grap the CP unit while you can, it would not surprise me if  Miller phased out this practical, low cost  work horse before too long. Ed

txtReplySubject:
Eds First Reply.Miller CP 302 or Invision


txtReplyBody:
jim as my books point out, with MIG wires or flux cored wires  there are only four practical wire feed settings required for any wire diameter on any metal application. The bottom line, if a weld decision maker cannot remember these four simple settings they should spend hundreds of extra dollars on that programmable wire feeder. Its much cheaper to spend $79 on my book.


txtReplyBody:
Rory the bottom line answer is No. A change in the bevel or groove dimension should have little influence on the mechanical weld properties. Be more conerned with the weld fusion.


txtReplyBody:
First your E71T-1 WAS A POOR CHOICE FOR FLAT AND HORIZONTAL WELDS. YOUR WELD DEPOSITION RATE WOULD LIKELY BE HIGHER AND THE WELD APPEARENCE SUPERIOR WITH AN E70T-1.

what is the condition of the steel you weld, if you can use metal cored wires you can use MIG wires which typically cost 15 20 % less. If  mill scale is an issue stay with the E70T-1. By the way why the focus on wire costs, all flux cored consumables are extremely cost effective, tour company would do better if they focussed instead on attaing maximum weld deposition rates from each welder. All the best Ed.


txtReplyBody:
Dear Ed,

thanks for ur advice. Since we do have certain vertical welding  and to make bulk order at best price we are using E71T 1.

Our steel is clean steel without any rust.

Any further advice from you, Mr Ed

akilan


txtReplyBody:
In the construction equipment shops in which I have assited I would set them up with an E70S-3, 0.045 (1.2 MM) MIG wire and an argon mix with 8 to 12 CO2 mix. You can produce single pass fillet welds up to 5/16 12 to 14 lb/hr. IF YOUR BEAN COUNTERS object to that $40 dollar cyl of argon mix tell them the cylinder provides over 3000 inches of weld AND PROVIDES Lower cost wires, no slag, higher weld depositions than you are likely attaining, and one tength of the weld smoke.


txtReplyBody:
Stacy go to home depo and look at the shelf brkts that cost next to nothing.


txtReplyBody:
please be specific with the welding question


txtReplyBody:
its nothing more than an argon with 25% co2 Regards Ed. FOr all position fcaw the argon mixes should typically be 20 - 25 co2. Ed


txtReplyBody:
YES. Also if you are MIG welding and you are using argon mixes a  switch from an E70S-6 to an E70S-3 wire would also not be an issue as both wires provide similar mechanical properties with argon mixes. 
  Its the switch from CO2 to an argon mix that would make a change in MIG wires require consideration. From an engineering perspective, it's completely illogical for your company to pay more for an off shore MIG wire. Remember weld cost reduction requires focus on weld deposition rates and arc on times. Good Luck Ed


txtReplyBody:
I have yet to see this article. I believe if you go to the MIG section and visit MIG gases you will read my thoughts on how affective 3 part gas mixes are. The bottom line, adding oxy does lower the tansition current required to change short circuit into spray. However if you evaluate most spray applications you will find the real world weld issue is that the weld fusion typically attained is marginal, therefore you have to ask yourself, what benefits are attained from lower energy.


txtReplyBody:
I am not contesting your opinion or advise. 

The article by the way was written by a honcho of some little company you may have heard of- Air Liquide, Canada. Clearly he spent some energy on it.

My question relates to arc physics rather than weld reality and therefore might be considered idle conversation. I was led to questioning if the total effect of CO2 on spray parameters was different than that of O2 at equal oxidizing potential in the Ar mix.

 I am not sure I understood the article, nor am I sure it was intended to be understood.

 I believe you will find September's Journal interesting. No place in the issue were your opinions blatently contradicted, but a casual reader might easily draw the wrong conclusions, I think. Perhaps the opinions and interests of various sustaining members are those being promoted.

 A table in the article I mentioned does seem to show your all purpose c15 steel mix produces the strongest welds.

Regards,
 d

txtReplySubject:
RE: Idle conversation about AWS journal gas articles


txtReplyBody:
d. I will have to wait till i read it. Ed


txtReplyBody:
WE DONT USUALLY GET INVOLVED WITH SMAW AT THIS SITE. I suspect at the end of the day these 3 electrodes are all weld the same. I think The "G" designation means made in accordance with the electrode manufacturer spec rather than with an AWS spec.


txtReplyBody:
Its nice to find a weld power source that  someone is happy with, Regards ed


txtReplyBody:
I would like to talk to the person in your organization who believes the Panasonic equipment is a good buy and provides less maintainence issues. For God;s sake whats he smoking, tell him to look inside the unit and count the electronic components. As the news on the Miller Invision is rarely good, consider the 300 amp, pulsed Lincoln power source. 
  When welding carbon or stainless, unless you are a salesman, its practically impossible to justify the higher cost associated with pulsed equipment THE REASON is simple no practical benefits will be attained.


txtReplyBody:
Lisa your company has obviously been caught up with a little sales bull. Your gas mix is all  salesmanship, you weld thin stainless, your weld issues would be to 
[a]minimize weld burn through, 
[b]minimize distortion 
[c]minimize oxidation. 
 It's completelely illogical to use a gas that contains helium which requires higher weld volts and provides high weld energy.

Your power source parameter requirements is beyond ridiculous. On this application with traditional CV MIG  equipment you would use the 
1 mm wire, an argon 2 - 4 % CO2 mix, or argon 2 oxy. You would weld at 160 TO 180 amps or a wire feed of  approx. 250 ipm (range 200 - 280 ipm), Weld voltage 14.5 to 17 volts. Fine tune the voltage for a crisp consistent crackle. Depending on the weld size and requirements the weld travel speed range would be 40 to 80 ipm.This would result in no spatter welds I would tell you how to get rid of the pear at the start, but I think its about time your company invested $79 in my MIG book. Good Luck. Ed    

Lisa for this type of ridiculous welding equipment I would purchase a wire feed monitor that will tell you the wire feed rate. Has your company purchased my books with this equipment and weld gas purchase they need to get a little wlding reality. Good luck. Edit

txtReplySubject:
RE: How welding life is becoming complex in England


txtReplyBody:
also ed, this unit does scratch start tig and stick. its a cv and cc machine with i believe a conventional power source not inverter,i think they use a chip to set the different processes and it had a push pull system built into it all you do is add a cobra or prince pull gun, i fed 50 ft of aluminum through it with out a hitch and was suprised cause i've tried feeding alum through 10 ft gun and never could. i paid under 2700 for the basic unit which i thought was a good buy(of course more for the gun)it welds alum beautifly. my only complaint so far is the manual(which they upgraded) and the connection of the guns(they should make them easier and quicker to change from the 12 ft that comes with it to the prince) also their people have been very helpful with any questions and suggestions. the computer on the unit has trouble shooting codes and a way to download future programs.sorry for being long winded
fred


txtReplyBody:
Tim these electronics are minimal and serve a good purpose, regards Ed


txtReplyBody:
talk to  your electrode supplier about inconel 622 or 625


txtReplyBody:
Why did your company bring in a hygenist, in the history of MIG welding carbon steels with argon mixes no one has reported manganese issues. Before being concerned with the weld wires I  would first be suspicious of the hygenist their qualifications, their equipment and techniques they used on establishing the manganese levels.     Tell me more about the test and where did they check for the alloy, how close to the arc etc.


txtReplyBody:
I'll give more information as it becomes available, but what I know is...  On 10 of our welders, all at different locations, he attached a monitoring device that clips to the welders belt with a tube running to a filter/collection device attached to the collar of the welders shirt.  What struck me as odd is that before he collected these samples he made the comment that he "expects he'll find high levels of manganese".  How would he know that?  He hasn't annilized anything yet.
This is odd to me Ed.  You know what we do here (Crenlo).  A500 steel tubing Mig welded with 0.035-0.045 Lincoln S6.
I'll pass on more information once I get the final report.
Regards, 
PWC

txtReplySubject:
RE: High Manganese levels detected in the breathing zone.


txtReplyBody:
Now I am really suspicious, I would bring in another hygenist.


txtReplyBody:
Do you mean the line in the weld center, the straight solidification line that is often evident in welds.


txtReplyBody:
its always best to present the steel spec designation (ASTM -----) rather, than the steel trade name. Its rare to find a weldable grade of "construction steel" that would require pre heat before welding. Why do you have a preference?


txtReplyBody:
Hi Ed. thanks for the quick reply. As to my preference for the abrasion resistant steel, I've seen the astm a-36 wear out in less than a week. And since the Industry standard is this type of quenched and tempered higher strenght steel, I need to know if there is any difference in weld procedure. I know that if you try to punch or shear this stuff, you are going to have a lot of broken punches. The uses include demolition grapples on excavators, logging grapples, and anything that digs in rock filled soil. Thanks again.


txtReplyBody:
Without knowing the carbon content but knowing  the application, I would guess a 400 F preheat, use low parameters, use stringer beads.


txtReplyBody:
After much searching I am unable to find an ASTM # for this steel but I have located its composition. Carbon is .12/.16 manganese is 1.55 chromium is .55 and molybenum is .55. I hope Im able to help.


txtReplyBody:
i suspect the ifo i provided is ok. go to the steels and weld consumables section of my site and find a steel with the equiverlent or close ally content, the weld advice is there


txtReplyBody:
Yes,exactly. This "centerline" is very pronounced.
Is there any way of minimizing this situation?


txtReplyBody:
The centerline is typically an indication of a "good balanced" weld why would you want to cahnge it?


txtReplyBody:
The Lincoln rep sounds a little uptight about the Hobart metal cored wire. However you have no justification for the meatal cored wire, the 
E70S 3 MIG wire and argon 15 - 20 CO2 will be as good as you ever want.


txtReplyBody:
The obvious one is a light lubricant grease something the texture of vasalene. Use pre-shaped disposal sheetmetal components to cover items that are easilly damaged. Encourage robot  operators to be responsible for daily robot cell and weld fixture clean up.


txtReplyBody:
get a copy of the AWS structural code and apply their fundamental weld standrds. Regards Eds


txtReplyBody:
If your weldments are made from 4mm or less material you may want to check into a copy of AWS D1.3.  It will be cheaper than D1.1 and an easyer read.
PWC


txtReplyBody:
I am familar with the research that went into this subject and as usual it has the tinge of salesmanship. Ref ozone, I dont know of one saftey or medical incident that has ever been reported in the industrial world. When I read unbiased research (thats research not funded or influenced by the company that makes the gas) that states there are real safety bemnefits, then I will get on the ozone bandwaggon.


txtReplyBody:
Typically the max oxy content is 20 parts per million.Contact www.hungtingdonfusion.com they provide a monitor designed for this.


txtReplyBody:
Oops, I am also using .035" wire, 4043 or 5356, depending on recommendations, this will be for a boat dock.

- Mike


txtReplyBody:
Your data is a little conservative if the parts are a good fit, try >400 -450 ipm with a slight increase in volts, Did you check the otimum alum data in the steels and weld consumables section?


txtReplyBody:
Ed,

I did see the optimum settings at around 150A and around 23V.  I also have a bunch of textbooks/manuals/engineering books that say a good place to start is around 120A and 21V at 350 in/min.  I am going to build mini versions of my final design with 6" long pieces to simulate all joints and I will let you know how I make out.  400 in/min will almost max out my machines wfs, I think I measured it at 435 max.  We'll see, thanks again.

- Mike


txtReplyBody:
The Gingery Press has some books on fabricating shop equipment:
http://www.lindsaybks.com/dgjp/djgbk/series/index.html
Presses are fairly simple, you might want to check out the presses available from Northern Tools, etc. on the web and copy them.


txtReplyBody:
You may have already made your purchase, but we use both the CP 302 and the Deltaweld for mild steel to 3/8. We love the CP 302, but one advantage of the Deltaweld is that we can pair it with a dual schedule gun and feeder and give our welders the ability to quickly switch between spray and short circuit in an application that uses both. You tend not to make that change as often or as easily when you have to turn that crank, and consequently may not use the most effective process. If you go this route, we have found Tregaskiss to have the best dual schedule gun and couple it with the Miller 70 series feeder which lets you store different schedules.

txtReplySubject:
RE: A Miller CP 302 or Miller Invision, MIG power source.


txtReplyBody:
Eliminating both the helium and hydrogen will have absolutely no impact on your weld quality or weld mechanical properties. As you are aware argon is "inert"  and the TIG welds and mechanical properties you produce result from simply  melting your base metal substrates. Changing from cylinders to liquid gas containers will dramatically reduce your gas cost and decrease your concern for cylinder gas contaminates. In terms of increasing weld penetration, in your thickness range simply using the correct eleincreasing the current should meet your needs. After making any weld or consumable cut the parts and make changes till you have attained the desired weld penetration. If your engineers are not convinced with the evidence of the complete weld penetration, they can waste your companies money and provide mechanical tests.

Ed.

txtReplySubject:
RE: The need for helium in our TIG application.


txtReplyBody:
This subject is covered in the alum section of MIG and flux cored data. To break up the alum oxides on your application the arc plasma must have sufficient intensity. Try the following lower the voltage till spatter start`s then add 1/2 a volt at a time till the spatter goes away. Try to increase your wire feed rate and increase your forehand angle. Try a larger gas nozzle and ensure the gas flow at the nozzle is 40 - 45 cuft/hr. Good Luck Ed


txtReplyBody:
I recently saw Polish cap welds on boiler headers. These welds were made in Poland and shipped to the US for fabrication to the boiler panels. There was no evident weld penetration as required by the ASME BOILER code. When we showed the CLEAR evidence of lack of penetration to the Polish engineers, they shrugged their shoulder and said the welds looked ok to them. 

You can apply any weld specification to your overseas welded application, however you will find the interpretation of those specs will change from country to country. It's noteable that the emerging third world countries will provide the most tolerant weld acceptence. 
 Why dont you apply some fundamental common sense requirements for the welds on your application.


Ref Acceptable Weld fusion requirements.
    Accetable weld consumables
    Approval of the weld data      
    Acceptable weld porosity 
    Acceptable weld size
    Weld qualification and testing of the    
    finished welds.

txtReplySubject:
RE: Comparison of AWS standards to European standards


txtReplyBody:
Aluminum has great affinity for weld porosity. 
The majority of aluminum weld porosity results from entrapped hydrogen gas in the weld pool. Hydrogen is highly soluble in molten aluminum.The hydrogen can be derived from many sources. 

[a] Hydrogen from base metal contaminates, hydrocarbons, lubricant, oils dirt, grease, moisture, paints and compressed air and contaminates from pneumatic cleaning tools.

[b] Hydrogen from lubricant contaminates on the alum weld wire surface.

[c] Hydrogen from moisture, water leaks in water cooled torches. Water from the gas cylinders. Water from the porous, hydrated, alum oxide layer on the base metal surface.

[d] Hydrogen that results from high humidty, condensation on parts and weld wires.

[e] Hydrogen that results from contaminates from grinding wheels.

To minimize hydrogen and weld porosity potential consider, cleaning, degreasing, stainless wire brushs or carbide wheels to remove the oxide surface. 

Remember you can always find porosity in the alum weld, the real question is how much is acceptable and what inspection and weld process control method will be used to control the porosity. 

Apart from clealiness. To reduce aluminum weld porosity potential, slow down the weld solidification rate to allow the hydrogen to exit. Reduce alum weld porosity with the following 11 points.


[1] To remove the alum surface oxide consider a die grinder (>30,000-rpm) rotary, coarse carbide file. An effective cleaning solution is actetone, beware highly flammable..

[2] Increasing weld parameters, with MIG increase the wire feed rate.

[3] Increase weld size.

[4] Avoid weaves.

[5] Slow down weld travel speed.


[6] Use smaller diameter MIG wires.

[7] Evaluate the weld procedure so that weld heat and weld sequence is used as a tool for porosity reduction.

[8] Use lowest possible MIG weld voltage. Low weld voltage results in short arc lengths which create more energy in the arc plasma providing improved arc cleaning action of the surface alum oxides.

[9]Use a higher energy gas mix like 60 helium - 40 argon. The helium requires higher weld voltage. The 60 helium mix is superior to the common 75 helium 25 argon mix, as the the higher argon content helps stabiilize the arc and provides superior weld cleaning action.

[10] Dont use MIG wire wipes clipped on the wire.

[11] Dont use anti spatter within 2 inches of the weld.

 by the way this answer is in the MIG aluminum part of this site "MIG and Flux Cored Data"


txtReplyBody:
Fred this site has taken me thousands of hours to develop. Why not visit the MIG section and look under MIG gases. Ed


txtReplyBody:
If you are welding stainless out of position, the higher deposition rate flux cored process is the most effective. 

If you weld flat and horizontal the regualr MIG spray and short circuit modes are the moat cost effective  Ed


txtReplyBody:
FIRST LET ME KNOW WHY YOU ARE USING THIS WIRE AND CONFIRM THE WIRE SIZE, PLARITY AND APPLICATION THICKNESS


txtReplyBody:
the wire is being used to eliminate porosity caused by occasional glass residue left over from blasting. The wire is 1/8, the polarity is DCEP and welding a lap w/different thk., thicker is 0.115 to 0.065. The glass is giving me fits, welding a circumferential bead, 14" diameter. Using C25 gas. Lincoln DC-1000.


txtReplyBody:
Why would you use this wire? it makes no sense.
call me  843 298 2054,


txtReplyBody:
I doubt you will get there with increasing the gas flow. Using regular spray tranfer instead of pulsed will provide a smoother weld surface. If you have to use pulsed, increasing the pulsed frequency, reducing the pulsed time or width, increasing the back ground current, will provide a smoother surface. Good Luck Ed.


txtReplyBody:
For a lap or fillet 40 degree angle 15 to 20 push wire tip 1/16 bqack from corner. Ed


txtReplyBody:
go to my home page and click on the TIG Data link.

txtReplySubject:
RE: Fundamental, automated TIG weld data?


txtReplyBody:
Clark

  Its been awhile since I worked with it. I found the E70S-6 had more silicon or managanese than the Lincoln wire, the result was the spray weld was a little too fluid, we were using automated welds on 1/8 to 1/14  steel. Also the arc was much brighter a greater intrusion to surrounding welders. A few years ago in auto plants I found many instances of inconsistent wire feed from the drums, i dont know if they have resolved that issue. It would not be my wire of choice. Good luck Ed.


txtReplyBody:
THIS IS A GREAT QUESTION?


 
       Its is derived from SMAW practice. As you know in pipe welds you can have a large vee goove to fill in and its relatively easy with fast freeze stick electrodes to weave. The probelem with weaves is the weld can become too thin and while solidifying crack. Also with large weaves we have very slow weld speeds which can result in excess heat to the pipe (larger grain growth) reduced impact properties. ASKING SOMEONE TO RESTRICT A WELD SIZE TO 3 TIMES THE "WIRE" DIAMETER MAKES NO SENSE, AS MIG OR FLUX CORED WIRES ARE ARE VERY SMALL AND THE WELD DEPOSITION RATE, TRAVEL SPEED IS HIGHER. A PRACTICAL RESTICTION FOR MIG OR FCAW WEAVE WIDTH WOULD BE 1/4 6 mm FOR VEE GROOVE FILL PASSES AND 1/2 FOR THE CAP PASS.
  Three times a stick electrode weave restriction does make sense.


txtReplyBody:
MOVE YOUR NOSE 2 INCHES TO THE LEFT AND VISIT EDS TRAINING RESOURCES.


txtReplyBody:
What make is the wire? Do you have a wire feed monitor. Run the wire for at least 2 minutes checking the consistency of the wire feed rate. Check the bore of the contact tip with the actual measured diameter of the wire. Release the wire feed rools and see how easy it is to pull the wire through the gun and contact tip. Make sure the wire is aligned over the center of the drive roll groove. You may need to use either a larger tip or a larger liner. Let me know Ed


txtReplyBody:
Yes you can use short circuit 15 to 25 CO2 ON AN APPLICATION LIKE THIS IN WHICH ITS UNLIKELY YOU WILL POST HEAT TREAT, I typically would use an E70S-3 wire. If you want higher strength E80S-2


txtReplyBody:
Wow, thats easy enough, thanks. I thought maybe the difference in metals would cause a corrosion issue. 
thanks


txtReplyBody:
Harris welco brand ER70S6 straight Co2
wire mic measures .034 in several places every time. threw 10' on the floor and it made a 3'coil and nice and flat.


txtReplyBody:
Don if you have covered all the possible things that can effect the wire feedability could you try the following. Set up to weld spray  transfer  with the wire  feed set  at 3 o'clock 28 volts. Use a spray mix. Get some 1/4 plate, Do a 3/16 or 1/4 fillet at  least 12 inch long. Keep a steady tip to work distance and watch what happens to the arc and plasma at the wire tip.  Examine is the plasma  moving up and down the wire. Is the arc and the arc sound consistent? Get back  to me Ed


txtReplyBody:
Don what  percentage of Chrome are we talking about? Ed


txtReplyBody:
Just a wild guess, but you might try the link for "Ed's Training Materials" that you see on the left hand side.


txtReplyBody:
Dont know much about chrome molly. Its black in color.USA ply tube mil-t-6736b 4130 cond 50309 po 900 70 s  are the numbers on it.


txtReplyBody:
VISIT MY MIG SPRAY DATA AND SCROLL DOWN TO ARC BLOW

txtReplySubject:
RE: Weld  dissruptions in the robot cell, is it arc blow?


txtReplyBody:
You can also make sure that the guide tubes in the wire feeder are clean.  If you're using a felt wiper, I would suggest using it dry.  The liquid cleaner/lubricants often cause more problems than they solve by attracting the ever present dust and gumming up in the guide tubes.

Dave


txtReplyBody:
Visit the MIG and flux cored data section the info is in the MIG spray or flux cored sections. ed


txtReplyBody:
I'm getting a handle on things.

I'm raising my preheat temp to 500F (if possible, I have it rigged on a propane barbecue). And will probably fill the present defects with a rounded patch of mild steel and a good ni-rod w/ rod suggestions from my weld supplies dealer.

txtReplySubject:
RE: Cast iron electrode selection - automotive cyl head <con't>


txtReplyBody:
Your electrode is likely ok. 
  DRILL A HOLE AT BOTH ENDS OF THE CRACK
  GRIND OUT THE DEFECT.
  Bevel out ground area.
  Pre heat 400 to 500 f
  Use stinger passes.
  Peen after each pass.
  And say three hail Mary's and two Our Fathers

txtReplySubject:
RE: Cast iron electrode selection - automotive cyl head


txtReplyBody:
<quote>  And say three hail Mary's and two Our Fathers 
How 'bout if I just put a rosary in mah pocket? 

Thanks. I'll get it yet. ;)


txtReplyBody:
Both Miller and Lincoln make good TIG equipment.  Look for equipment features that will benefit you. TIG equipment that can weld at one amp is fine if you are welding 0.001. Are you going to weld THIN aluminum, if so pulsed may beneficial.
 Yesterday I trained an individual to TIG weld  stainless and inconel parts 0.020 to 3/16. I used a twenty year old MIller power source and the tube and plate welds could not be better. Bottom line I like Miller. I would recommend you pay for current. So many first time buyers of weld equipment purchase toys instead of DURABLE weld equipment that provides SUFFICIENT weld current.


txtReplyBody:
I have not used these two pieces of equipment.Maybe some of the guys have. Ed


txtReplyBody:
For a fillet weld go with the 5356 its much stronger. For butt welds the 4043 and 5556 are similar and with butt welds on these alum alloy you would expect the parts to fail in the HAZ rtaher than the weld.


txtReplyBody:
Rory. Figure out the weld deposition rate.If you had gone to the steels info section at this site and clicked on alum you would have found the 046 wire x 0099 = lb/hr. At 500 ipm,5 lb /hr which is equivelant to a low weld dep, steel short circuit weld. My books inform you that the typical carbon steel spray transfer weld is made with an 045 wire at a feed 400 - 500 ipm  11 - 14 lb/hr, delivering a weld travel rate 17 to 20 ipm. 

   So now you can understand with alum and the 1/4 fillet welds, you have large wire feed rates and a low weld deposition rates = low weld travel rates. The higher the wire feed you can go the more weld energy you generate therefore the less weld fusuion issues. Frankly I would be using a 1/16 wire. And one day in this great country, the brain dead alum wire manufactures will produce an 052 wire.


txtReplyBody:
Consider every weld made on zinc coated metals to be a contaminated lake. The water may look ok however drink it and you are dead. 

  All welds irrepective of the weld process used, when made on these coated metals will have excessive porosity, and have zinc, alloy  oxide reactions in the weld grain boundaries. That's the reason you are not supposed to use E70S-6 wire, the extra silicon adds to the zinc and increases the opportunity for micro cracking. Of course we all know that in the auto industry the number one MIG wire choice for zinc coated applications is an E70S-6. As most of these welds are made on auto and truck parts which frequently have dubious quality welds why worry about a little zinc added to the pot.


txtReplyBody:
Ryan. Its a dangerous practise to create an arc in a liquid you have no information on. Your employee is breaking the law (OSHA) by not supplying MSD sheets. As you know I have been MIG welding for more than 35 years and weld spatter has never been an issue. Maybe you can convince your manager to take the money he pays for anti-spatter liquid that contaminates his MIG welds and provide the welders with weld process control training books so they can produce MIG welds without spatter. By the way any light oil mixed with water makes an  optimum an anti spatter mix. However its about time weld shops learnt that water oils and welds are not compatable.


txtReplyBody:
Dear Ed:
       Thanks for reply.Your meaning is :a welder can get a good weld with traditionary Mig ,but this depends on his skill,isn"t it? If so ,then how to set the parameters and choose the right wire ?Is this simple ?And where can I get these informations?In USA ,the most useing in stainless is what,Mig ,pulsed mig or flux-cored?


txtReplyBody:
try TIG or MIG with aluminum bronze and straight argon

txtReplySubject:
RE: can I weld aluminum to galvanized tubing?


txtReplyBody:
So Fred, I'm confused.  Are you running a 50ft Python, or a 50ft Prince?  You mentioned both, I think.  Obviously, big difference between success at that cable length with a spool gun versus push-pull.  Let me know, as I ordered my Power Mig 300 last week, and expect it the day after Christmas.  (I'll let Santa deliver to all the kids first.)  I specifically chose NOT to go for their 2177 package with the Python included for 3 reasons: 1. I wanted the Magnum 300 normal mig torch for everyday rough and tough.  2.  It turned out to be less expensive a-la-carte (at my supplier), And 3.  Most important as it relates to your experience: I thought I might buy the 50ft Python instead of the standard 25ft.  If you had success with the 50ft PYTHON (as opposed to the Prince), I will proceed with this plan, else I'll stick (ahem, I mean push-pull) with 25ft.


txtReplyBody:
For those guys that come to this site and some sales man or brochure makes a MIG bells and whistle claim please rember this simple fact. "MIG equipment made 30 years ago did not require a single bell or whistle to generate a perfect MIG weld. What is the 'Diamond Core Technology' I believe its Pure marketing power source drivel. If it was me I would be looking to get 50 - 100 more amps in the power source. 

   Ref: Lincoln claims on the tachometer monitoring system in the wire feeder which corrects for variations in wire speed.
 This feature is simply not necessary with a CV power source which has  a self correcting arc. Set the wire feed control adjustment correctly  and this Lincoln feature has not been necessary since we had CC equipment with variable wire feed controls back in the sixties. One thing about Lincoln they know how to pile it on.


txtReplyBody:
Thanks Ed, for your quick reply.  I kind of figured this was purely a marketing ploy.  I sent for your MIG training book and am looking forward to reading it.  I am limited to single phase power so 250-260 amps is my limit, as I cannot afford an inverter power supply. This machine is not my top choice, but it will be good enough to get me by for a while.


txtReplyBody:
Does your comment re: contamination apply to weld-thru zinc primers as well?


txtReplyBody:
How does one know when a new "bell and whistle" actually adds new value?  Is it possible that when MIG welding itself was introduced, traditionalists of the day may have scoffed? Did they point to their stick electrodes, or gas torches, or even their funaces and bellows and say that metal joinery need not the wizardry of sheilding gas and continous wire supply?  Muscle cars of 30 years ago went fast and were made with thicker steel and more of it.  But cars of today are lighter, just as fast, and are safer with crumple zones, air bags, ABS, less noxious fumes, etc.   Remember how traditional drivers disliked ABS when it first appeared?  The pedal pulsated, which they weren't used to.  Since their old car stopped "fine" without ABS, "it must be just a gimmick" they scoffed.  Not so today.  So, how can I determine whether or not "pulse on pulse" and "chopper technology" etc, are not the ABS and airbags that will ultimately define the minimum standard of MIG processes of our future?


txtReplyBody:
Carl 
 I just completed some experiments producing spray transfer with my Millermatic 210 that turned out to be successful. The material thicknesses for these tests were 3/16" and 1/4". The wire was an .035 E70S-6. Shielding gas used was 98AR/2O2. Wirespeed for the 3/16 material was 370-380 IPM. Wirespeed for the 1/4" material was 410 to 420 IPM. Sorry to say that I don t know my actual load voltages. No one was around to measure them for me. The MM 210 is a 7 tap  voltage selection machine. Anyway, for the 3/16 material I used tap #6 and for the 1/4 I used tap #7. As a side note,on the 3/16 material I tried tap #5, and achieved that same type of metal transfer that Ed's demo shows here on his site. In closing I need to state that this machine is used for my personal home use this way, and gives me about a 30% duty cycle in this range, which is far from ideal for a production enviroment.


txtReplyBody:
Robyn you miss the point entirely; a useless bell & whistle is one which provides no PRACTICAL benefit.
 To some extent Ed is criticizing prescribing the wrong wonder drug for the malady at hand; eg:he's not against pulsed- he's against the rationale often used to justify the need for pulsed. If you can achieve as sound a weld at equal or greater speed and economy with present technology the feature presents no practical benefit.  

 Free yourself from your confusion; THE TRUTH SHALL SET YOU FREE... if you can do it as well without it, you can do without it...
 ...Ed can back up his claims better than the Madison Ave advertising agents trying to get your money. You should read more of what he has to say and test it to see if it isn't true. The guy's trying to keep your money in YOUR pocket; smell the coffee. 

Regards
d


txtReplyBody:
Ref Doubting Thomas. If you cannot find enough evidence at this site all I can add is "a weld is a weld". Read less weld equipment marketing hype and weld more. ED


txtReplyBody:
Yes it applies as long as zinc is an alloy


txtReplyBody:
It does an excellent job on alum bronze however its a three phase machine. Ed


txtReplyBody:
CArl, thanks for the review.  I wasn't sure which book I wanted, but now I do.  Ed's advice is right on the mark.


txtReplyBody:
Here are answers to your two questions.
1. "Diamond Core" is a marketing catch phrase for a patented transformer design that provides an automatic variable inductance control built in to the transformer.  If you are unsure what inductance is, it has to do with the magnetics of the arc that determine the size of the metal droplet that comes from the arc.
2.  The Tachometer acts just like you said, it helps keep the wire feeding consistantly at the same speed.  Machines that do not have a tach simply change the voltage to motor to change the wirefeed speed, effective but not as consistant.


txtReplyBody:
FYI - That Harris Welco Wire is Junk - Very Inconsistant.  Try something top of the line and see if your problems go away.


txtReplyBody:
FYI-  IT is not conventional, it is inverter/chopper based. (THis is not a bad thing)
I would not recommend switching back and forth from a standard Magnum gun to a push pull gun.  Each time you change requires lots of time a potential to lose several parts (springs etc..)


txtReplyBody:
Weld Fact:  Variable inductance has  been around  for decades and anyone who is  aware  of inductance  would  know that  with short circuit welding there is typically "one" optimum inductance setting.  
  In the 1970s and 1980s we had many machines with variable inductance, then in the nineties some MIG equupment manufactures figured out that you could set a fixed inductance out put to meet the majority of short circuit applications. The bottom line is this power source with it's capabilty to provide different inductance out-put cannot do a weld any better than a good MIG power source that does not have this feature. Again I repeat, perfect MIG welds can be produced with equipment that does not have these Lincoln bells and whistles.


txtReplyBody:
My deal on the Lincoln fell through, so I ordered a Miller 251 with 15A spoolgun.  Hope to be breathing smoke by next Wednesday.


txtReplyBody:
Glad you got the Miller.  I think you will be happy with it and the spool gun.  If I was in the market today, my choice would be the 251 or the vintage.


txtReplyBody:
The multiprocess MIG equipment is functional however uou will not get the  same MIG arc results
as that attained from a  CV power source with a slope out put dedicated to MIG. Lincoln or Miller, you know my preference it's blue


txtReplyBody:
I may have been misleading by saying all in one. What I should have said is the popular migs that roll around or can be carried from place to place. Like the ones in the 135 to 300 amp range. Or do you mean that the better machines  are the ones with a power source connected to a seperate feeder. I was talking about the machines that roll around on wheels from place to place. Iam sorry if I was not clear. Thanks Matt


txtReplyBody:
Matt I believe you mean the Invertors.
   Typically an Invertor has a steeper slope than a traditional CV power source. A good way to test an invertor against traditional MIG equipment.Use an 035 wire 15 / 20 co2 gas. Try the 9 to 12 o'clock, short circuit  wire feed positions and note the voltage and consistency (crispness) differences of the arc. Then try the 1 to 4 o'clock spray positions, again note the volts / amps and fluidity of the weld metal. 

 If you tried a typical 250- 300  amp Invertor against a good lower cost 250 / 300 CV power source you would want to purchase the traditional mig EQUIPMENT. The only real practical adavantage of the Invertors is their smaller size and lower weight.


txtReplyBody:
Matt, in the 250 amp range, I would look hard at the Miller Vintage.  It is still on their website but I understand not in their 2003 catalog.  I have read a lot of good press on this one from users.  If you want something smaller, then look at the Millermatic 175.


txtReplyBody:
What you meant about "all in one migs" was very clear to me, as I just lived through this new equipment purchase angst.  The 'ol MillerMatic vs. PowerMig debate.  Blue vs. Red.  Despite Ed's abundantly clear and relentlessly consistant personal bias against the Lincoln Electric Co, (for whatever reason??), I chose the PowerMig 300 ironically in part due to Ed's simple advice:  Get More Power.  Buy More Amps.  

The MillerMatic Vintage, Pulsar, and the 251 all offer appreciably less power and lower duty cycle at their rated power than the PowerMig 300.  For example, Miller's top of the line single phase machine, the 251, only offers 200 Amps at 60% duty cycle, whereas the PowerMig 300 offers 300 Amps at 60% duty cycle.  The 251 can deliver 250 Amps, but at only 40% duty cycle.  The 300 delivers 230 Amps at 100% duty cycle.  Despite the other features that the 300 offers, it is a more powerful CV powersupply.


txtReplyBody:
Robyn,
 You keep throwing stones around here and missing the point. Ed's seen a lot of welders all over the world, probably more than the number of welds you've made. His preference seems not to be so much a particular model or machine itself but includes the entire support net, even the personnel at the factory level when things are in worst-case scenarios, and his overall evaluation of how responsive the company is in a lack-of-bull context. Its a little silly to compare your vast thimble full of experience to his and suggest they are equal, isn't it? Use some logic and see how you got out of line here.
What exactly is your problem with Ed's personality? You would be better off if you asked  WHY your opinions apparently differ. I know Ed; he's no moron. Perhaps your credentials would give  more confidence...?


txtReplyBody:
Robyn

   The first thing you see when you arrive at this site is a picture with this statement.
"Lets get the Bull out of Welding" 
   In the decades I have been in this industry, in my rolls in marketing, weld engineering and process training with companies like, Airgas, AGA, Linde,Liquid Air, and Carbonic, I had numerous dealings with the Lincoln management. There are many reasons why I have minimal respect for Lincoln, and I believe this site informs you of many of those reasons.  You will understand as times goes on. When Lincoln has a MIG or flux cored product which I believe is note worthy I certainly will indorse it. By the way on this site last year I identified Lincoln as having the best traditional CV power source in North America and having the best MIG wire,(when its made in the USA) What more do want from me. Ed 

 Before you can recognize the smell of bull shit you have to be around it and tread in it.


txtReplyBody:
Ed, it sounds like you had unpleasant experiences with Lincoln management, but it also sounds like you were in a position with other companies at that time that does not typify what the average buyer or user of an all-in-one mig would have. The “reality” is… that apart from your welding career, you are an extremely effective writer/communicator, and have produced a well organized website on welding that crops up in any search engine on the subject. As such, your unique and briskly articulate opinion, which I would die defending to your right to have, is magnified among readers with a force and power that no doubt exceeds the amperage of your dream CV power supply. Therefore, you might expect your words to influence buying decisions, and in this case, your opinion of a company based on your past corporate level “dealings” might preclude the originator of this thread from considering what could be the most powerful single phase all-in-one welder currently available.


txtReplyBody:
"d" said: "your vast thimble full of experience" "you keep throwing stones" "use some logic" "a little silly" "you got out of line" "what exactly is your problem with Ed’s personality?" My problem is not with Ed’s personality, it is with yours, "d." I’m not expecting the red carpet here, but I could do without the red smear. Ed seems capable of clarifying his own positions without resorting to personal attacks. In your unsolicited defenses of Ed, why can’t you? When and where did I ever "suggest" that my experience was "equal to Ed’s?" How do you even know "the number of welds that I have made?" My credentials? I only have two that are important in the context of these conversations. 1) That I am always willing to learn, and 2) That I am always willing to question what I have learned. These credentials may not give you any more "confidence," just less reason to stretch my questions out of context.


txtReplyBody:
Robyn,
 In about 3000 words I was able to compose a more balanced response. I can only post 1000 or so. A lot was lost in late-night editing. I'll try to change my tack as I am sounding as bad as what I am complaining about, and there is no way I can figure out to remove what was posted. Nevertheless fact remains. 
 Your tone seems so caustic when I read it that I get overcome by what I'm reading as a prejudicial attitude; it's annoying. Maybe its me? I am forward enough to try to politely say these are the reactions you are inciting- it's for you to decide if they're the reactions you wanted. As I cannot edit after the fact correct it to be as courteous as you'd like.  End of chatty posts-email if you feel the need. Best to let it end, remaining under advisement


txtReplyBody:
as the box has stood up to the corrosion its likely that an incorrect electrode was used the first time. Weld with 316L and you should be ok


txtReplyBody:
If its just MIG get the MIG Train book, if its MIG and flux cored get the red book and if you are going to spend the rest of your life in this industry and want to rise up out of the weld smoke get the Management book. Good luck Ed


txtReplyBody:
Remember that with the thin stuff you can't run continuous welds; you have to do multiple short ones.


txtReplyBody:
Frank, the gage you are welding is about as a low as you want to go with short circuit, this thickness combined with gaps is going to always create weld burnthrough issues with the traditional MIG process. However if you used an 035 aluminum bronze wire with straight argon, the lwer melting temperature bronze wire with the low energy (easily ionized) argon gas will weld without concern for weld burn through. The bottom line, you have two choices, [1] get this more costly wire approved for your application,  [2] fire the stupid designer of this welded  part. Ed


txtReplyBody:
The ideal E71T-1 VERT UP wires are either the 045 or 052 (1.2 - 1.4mm). These wires when set for optimum vert up welds on the applications you mentioned,  typically will provide a weld deposit rate of 6 to 9 lb/hr. In contrast the deposition rate of SMAW is approx 1.5 to 3 lb/hr

txtReplySubject:
RE: Deposition rate with flux cored wires versus SMAW


txtReplyBody:
Steve do you have to purchase the invertor? You may want to consider  a 600 - 650 amp unit, this will be more durable and deal with the heat. Both traditional CV equipment and invertors which can interface with the robots are available in this amp range. Miller / Lincoln or ESAB all provide good duable equipment when you stay away from there bells and whistles. I would give each of your robot personnel my self teaching Robot MIG Process control books and sit them down in the classroom with the video. Its nice to see that a little welding commom sense has awakened in the global insane world of welding. Good Luck Ed.ps Let me know what you purchase.

txtReplySubject:
RE: robots and lLincoln Power Wave alternative?


txtReplyBody:
After I read the article I had too laugth for about ten minutes. The weld reality is most auto plants have a difficult time manufacturing steel coponents that can maintain good dimensional tolerances for the forgiving MIG process. 
  I have been in many plants in which the robot weld gap tolrances were in the range of 1/16 to 1/14. I find it hard to believe that this same industry who by the way employs few people that can optimize the two control MIG process is now thinking about a laser /MIG process. I can guarantee you that if the MIG process is optimized, the lack of down time benefits alone from the MIG process will compensate for the weld speed differences.  The bottom line, the decision to bring lasers into auto /truck plants at this time is nothing more than corporate management madness. Ed

txtReplySubject:
RE: Lasers  and MIG combination for auto plant?


txtReplyBody:
Alan it simply depends on the the gage thickness. Argon good question. Argon - 10% C02 is a superior short circuit gas mix to higher CO2 mixes, that is if the parts welded are <0.060. 
On these thin parts avoiding weld burnthrough is the key weld issue. The low energy 10 % CO2 mix when used as a short circuit gas is as good as you can get for the thin gage parts. 
  When the short circuit welded parts are in the thickness range of >0.060 to 0.100, more weld energy is required in the fast freeze short circuit weld. In this thickness range 20 to 25% CO2 is ideal. By the way I believe this topic is covered in the MIG gas section of this site.
  Regards Ed


txtReplyBody:
When supervisors recommend weaving for commom MIG welds it typically means the supervisor has more SMAW process expertise than MIG expertise.

Weaving is ok with SMAW as this low dep process alows the welder "time" to direct the arc. 
  Weaving should not be done on traditional butt and fillet welds with the FAST FREEZE, SHORT CIRCUIT ARC ON / OFF PROCESS. IN THESE CIRCUMASTANCES the weaves will add to lack of weld fusion potential and thin out the weld bead  adding to center weld crack potential. When short circ welding weaving is necessay only for gaps. In the spray, weave when welding a 5/16 fillet. If welding pipe ensure the minimum weld weave depth is >0.100. For pipe weaves a slight osscilation in the weld center typicaly provides better fusion controll. By the way your application dictates that you should be using a controlled globular mode rather than short circuit. 
   Get this supervisor to vist my site and invest a few bucks and read a little weld reality.


txtReplyBody:
what is the stickout you are using, its possible a shorter stickout will provide more energy and reduce the porosity.

txtReplySubject:
RE: Voltage settings on Invertec 350 using Fluxcore


txtReplyBody:
The stickout is between 3/4 and 1 inch.
What about the voltage settings? Do you have a comment on this?
Thanks in advance!


txtReplyBody:
I recently purchased a MM251 and really like it.  I also purchased a copy of Ed's book, which is also quite helpful particularly when dealing with spatter.  1/4" should require the welder to be set up for spray transfer, which they say is nearly impossible with Ar/co2-25%.  Ed's chart lists Ar/co2-15% as a preferred gas, with wire speed set at 3:00 (560 ipm) and voltage set at 31 volts.  I have never used the Ar/co2-15%--I just settle for transitional spray.  If you set up your machine like Ed says, you had better be ready to weld--his settings are designed for production work and doing the best job at the most rapid speed.  I would highly recommend getting Ed's red book--I have learned a lot from it.


txtReplyBody:
Oops, forgot something--excess voltage is the main cause of spatter in short circuit transfer.  Insufficient voltage is main cause of spatter in spray transfer.  From your settings I would say you need to bump up both your wire speed and voltage.


txtReplyBody:
Its normal to have to put two to 4 volts ocv to attain the weld volts . If the stickout is correct and an amp and volt meter shows the parameters are in the recomended electrode parameter range, the excess porosity from a new wire would typicaly indicate a poor consumable or a consumable that has had a long shelf life.


txtReplyBody:
Mat the settings you have are short circuit wire feed rate with  globular voltage, do you have one of my books?


txtReplyBody:
I am not a fan for the self shielded wires when they are used "indoors". For out door i would use the self shielded on construction work and gas shielded flux cored on pipe. 
  Many of the self shielded wires in use today were developed by Lincoln decades ago. The majority of of these products had terrible arc charateristics, excess spatter, teneacous slags and weld smoke you would not want to analize. Also many of these so called all position wires were simply too large so a vert up weld on plate <5/16 was difficult to control. 
  If I was interested in a self shielded flux cored wire for general construction use , I would contact Lincoln , Alloy Rods Tri Mark,  ESAB and ask for their best multipurpose, all position, self shieded wire that will meet min 70K tensile. I would then  compare these products by welding a 1/4 vert up fillet weld on 1/4 plate weld. My guess would be that Lincoln does not come first.


txtReplyBody:
You are going down a road you dont want to go.
 If you have a domestic wire thats working for you "keep it" and tell the purcahsing people to stop trying to save a few pennies per lb on the weld wire and go and look for another drogon to slay


txtReplyBody:
HAving spent many years in Purchasing, I can tell you that often the Purchasing guys would rather leave the status quo, but the experts in the oval offices force them to try to cut costs which in turn costs more down the road.  The problem isn't limited to wleding consumables but includes many other safety sensitive areas as well.


txtReplyBody:
weld vert down with a 90 degree to slight push gun angle

txtReplySubject:
RE: 18/16 gage stainless butt and corner welds


txtReplyBody:
Good afternoon Ed:

My name is Ken Muench and I work for the Navy Crane Center in Lester, PA.  I am currently working on the overhaul of a 50 Long Ton Portal Crane in Rota, Spain.  Our specification requires the contractor to use the AWS D1.1 welding code but the contractor has proposed the use of European Welding Codes, namely UNE-EN 473 and CEN/TC 137.  Can you tell me if these codes are equivalent to the AWS?  Is there a way I can get an English version of these European Codes?  What ever help you could provide would be greatly appreciated.  Thank you for your time and effort.

Kenneth V. Muench


txtReplyBody:
Ed what a challenge. 
                    You are right to be concerned.
 Typically an application like this would be done with SAW or edge prep MIG / FCAW. I believe that with TIG the weld speeds you desire may be attained with a multi-torch combination, however the concerns on any high TIG application of course will always be on the tungsten wear and contamination. Then again you could consider multi torch plasma using both the key hole and fusion modes, this would greatly reduce the opportunity for defects. What about the inside of the pipe is it protected from oxidation. The bottom line its a challenge but I believe it can be done.

txtReplySubject:
RE: Welding heavy wall stainless(.500 ) on tube mills


txtReplyBody:
DUMMY!
As soon as I posted the question I found the article under MIG and FLUX, and scrolling down the page to weld gas.


txtReplyBody:
It was in WDF however I suggest you direct your energy to something thats real and practical. Ed


txtReplyBody:
Mr Craig,
I too have considered a multi-torch combination, however,what still remains a concern to me is the high amperages. Using Helium in these torches at these ranges I believe will degrade the tungsten electrodes at an accelerated rate. I am considering using 1000 amp tig torches using solely Argon as the shielding gas for each torch. 
The inside of the pipe will be welded simultaneously using a Helium/Argon mix(primarily Helium). The inside diameter shall also at the same time be sealed and purged with Argon gas.
Am I on the right track or way out in left field somewhere?
Again any assistance will be greatly appreciated.
If you have the time and you are interested in this project I would be delighted if you would contact me at my company email address or perhaps over the phone. Again, "Thank You".

With regards,
Edward R Cauffman
Welding Engineer


txtReplyBody:
I think what we are discussing is weld suface freeze lines. A MIG spay weld should have a smooth weld surface however thats no guarantee of consistent weld fusion. When a weld has dominant freeze lines and a scalloped, pie  shaped edge thats an indication of lack of weld fusion.


txtReplyBody:
What I'm reffering to is short arc where the weldor weaves the torch, either flat or  out of position, to get the stack effect.


txtReplyBody:
Alan the only time i have ever seen a need to short circuit weave or backstep is when welding a gap,an application requiring minimum weld arc energy. Weaves, back stepping or weld skipping take the weld energy away from the leading edge of the weld, you thin out the weld and distribute the arc energ over a wider area. Obviously this is a lousy practise with a low parameter weld mode process in which the arc goes on and off many times per-second  during a weld. These techniques simply add to the  lack of weld fusion potential. Ed


txtReplyBody:
I should have also said the short circuit skipping would be benficial on parts less than <0.040 that are prone to weld burn through.


txtReplyBody:
Ken

    In contrast to MIG (steels), pulsed TIG is a very good feature for weld and fusion control on all alloys. With pulsed TIG the primary parameters are peak - back ground current . The freq is how many time per-second you want the current to go to peak. The time or pulsed width is how long do you want to hold the current at peak. For thin applications you would want low freq and low time and for thicker applications reverse. If wanting to produce the distinct alum pulsed apperance you see on bikes you would have a very low pulse freq. With pulsed when you change one parameter it has a large impact on the other parameters. Increase pulsed time and you decrease pulsed freq. Check out the Feb Weld Design Fab magazine in my QA section this topic covered. Ed


txtReplyBody:
cannot help you on the book side  there is very little practical process control stuff out there. My advice for process expertise and career advancemet,   believe what you see, stay focussed on the bread and butter processes, be familer with ASME and AWS codes, keep reading about lasers, keep reading about a process till you believe you could write and article that would be published, never tell  a welder how to improve a weld unless  you  are prepared to show him, keep  focus on robot weld data, avoid the advice  of sales people, and in your head know how to work out the cost of a weld, be honest at all times and if some one asks  a question  and you  dont know the answer, dont offer an opion. Good Luck, ps. IF  YOU FIND GOOD LITERATURE LET ME KNOW. I hope you get Weld Design Fab and the Weld Journal magazines each month.


txtReplyBody:
The bottom line if you can be above the minimum  voltage range recommended for the wire selected and you are welding and pleased with the electrode and power source performance, isnt that all that matters.

txtReplySubject:
RE: Dissagreement with Lincoln Tech Dept.


txtReplyBody:
Do you know their URL?  As usual, detailed information, just what I needed to know...keep up the outstanding work.....Ken Allen


txtReplyBody:
the bottom line with the right consumable "yes"

txtReplySubject:
RE: Is tig welding chrome-moly the same as it is for stainless?


txtReplyBody:
What current level are you acheiving with the V350 plugged into the R8?  If the R8 generator at full power is 35a at 230v, and if that is the input power to the V350, isn't that input power only capable of producing output of about 80a welding current? Does .068 203MP at 20CV typically feed at 120ipm?  Does that wire speed need about 225a?  Even at a minimum of 70ipm, is at least 145a desired?  Is it possible to determine weld quality by looks?  These are just questions... I don't have the answers.


txtReplyBody:
Jack this application does not need the weld enery generated by either the STT pulsed / short circuit modes or from the costly high energy helium tri mix. Your company would have saved  thousands of dollars if it had purchased a regular CV MIG power source and used short circuit and a two component argon mix. I guarantee the weld burn through issues 
would have been reduced. O well BS wins out again. Regards Ed.

txtReplySubject:
RE: three part mix  and STT  stainless exhaust?


txtReplyBody:
Good questions....I guess I was assumming an input of the full 8000 watts of power from the Ranger 8.


txtReplyBody:
You are not getting sufficient current or voltage from the power source which suggests you have a power source problem or input power problem. Use a volt meter and set the wire feed and voltage at max. Check the volt output it should be 30 plus  volts. If the volts are ok you have damage inside the power. if the volts are low check inside the power source for the correct volt input.  Also check input power.


txtReplyBody:
"I guess I was assumming an input of the full 8000 watts of power from the Ranger 8."

So was I.  And the full 8kw still means only 35 amps at 230v single phase input power to your Invertec V350.  Could the V350 rather see 50-65 amps input current to comfortably produce adequate welding current at the suggested voltage for the 203MP wire?  Have you plugged in the V350 to a shore power circuit rated for 50 amps or higher (as recommended) to eliminate any faults with the 203 wire, LN-25 feeder, and/or Invertec 350?  Is it possible to rent a 15kw generator for a day to verify if better results are possible, and to witness how the V350 converts (rather than creates) power?


txtReplyBody:
How about I just trade the Ranger 8 for a Ranger 250 or a 305?


txtReplyBody:
Ernie I developed and hold  the patent on contact tips that are half  ceramic half copper. I designed and develeloped these tips(and nozzles)  to extend the  wire stick out for high speed welding on metals <3/16. I did not develop them for weld spatter issues. As you know in my world we do not have weld spatter issues. By the way spatter will build up on ceramics just as it will on copper. Over the last four decades I have seen many attempts to design tips that last longer, again I have  never had seious tip issues. The best way to improve tip life is provide weld process control training to the persons  who handle the MIG process.


txtReplyBody:
Thanks for the info.
I've had a chance to read some of your articles on this site, all very interesting.  A freind of mine and I had a real good chuckle (hearty laugh) over the TIME gas, (see my earlier posting).  I met John Church almost 20 years ago when he first "developed" his process.  I learned just how much snake oil is still being sold in the welding industry.  I still thank myself for not having bought into his story and put money down.
When it comes to tips and nozzles, beside buying OEM, do you have and advice?
Thanks  Ernie Krause


txtReplyBody:
Ernie is your concern with robot data and do you hav my MIG process control book? Ed


txtReplyBody:
Ed, 3/16" ss316 10ft diameter ducting, do you think if we square butt, 1/8" root opening, no bevel and do short circuit mig downhill on the ID, then on the OD back grind and do 2 pass short circuit downhill? We need to pass Xray. Would you suggest all position stainless .035 fluxcore on the OD downhill? or uphill? 
  You could do this readily. Instead of short circuit or flux cored try spray. Use a gap 1/16 - 3/32, and use the low end of spray parameters
with an 035 wire try 450 ipm at 22 to 25 volts.


txtReplyBody:
Thanks Kevin we all appreciate this type of advice. Ed

txtReplySubject:
RE: Safety warning on  Hydrogen Mixes for stainless TIG welds


txtReplyBody:
I'm afraid I don't have any of your books.  The best one I have is by Lincoln Welding.  The place I'm at right now has three robots and about six mig weld stations.  Most of what they have done is pretty good, bulk gas, a quality weld wire, some interesting ways to hold their fixtures to improve position.  We will shortly try a different weld gun, to try to go to an air cooled from water cooled, and all those problems.  I saw too much spatter build-up on the tip and inside the nozzle and remembered an old ad that I saw in a magazine a long time ago.  The contact tip had what looked like about a 1/4" of ceramic at the end.  I just thought it might be one of those small incremental inprovements, to reduce the stop time for cleaning, and reduce the wire wear at the end of the tip.  See next.

Thanks      Ernie Krause


txtReplyBody:
The thought came from earlier experience that tells me it costs about $5 and more to change a tip, by the time you factor in stopped time, grinding out and repairing the last few inches of weld, etc.

Thanks    Ernie Krause


txtReplyBody:
Check to see if the bore in the contact tip is not too small or the wire diameter is not oversize, check it out run the wire through the tip and check for clearance, should be approx 0.007 to 0.012 clearence. 
  If wire or tip is not an issue its likely your current is hot for the gun, I assume that you are not welding short length welds. Also check to ensure all the gun cable connections ok and ensure contact tip is recessed inside the nozzle 1/4

txtReplySubject:
RE: Spray with Tweco #4 gun- heat issues


txtReplyBody:
650 ipm or the 5 o'clock position, 25 to 26 volts, 30 to 35 ipm argon with 15 to 20 co2


txtReplyBody:
That 400 amp rating you guys are duscussing is a product rating thats designed for straight CO2 use not argon mixes,(which attain spray and run hotter). Its another one of those obsoete stupid weld product spec quirks perculiar to our weld equipment manufactures. Ed


txtReplyBody:
Ed, how much do you de-rate a gun for C-25?


txtReplyBody:
I kow with a 400 amp. air cooled Tweeco weld gun  with an 045 wire and a moderate spray setting of 280 amps, that  I would likely consider a water cooled gun if I had many welds to do that were longer than 6 inch


txtReplyBody:
So my Tweco #1/.035 wire with spray on a 250 amp machine is not a real good idea?


txtReplyBody:
Alan the bottom line is its all about duty cycle. You can weld all day long if the weld lengths are short. If the gun feels too hot when you are holding it its likely you need the next size gun


txtReplyBody:
Ernie if your company employees all get together they could have a collection and purchase a $79  robot process controll book and with the information attained, especially in the robot weld start and end data they can dramatically reduce tip changes and down time.

txtReplySubject:
God what do I have to do to get you to buy a welding book


txtReplyBody:
These tubes are typically approx 0.040 thick. Use one amp per thousand thickness minus 10%


txtReplyBody:
jp. The choice should be a simple one. In the one hand you have a power source that costs $10,000,00 with no spatter issues, low smoke, and fast arc resposnse, in the other hand  you will be able to buy a power source for seventy percent less, spend an additional $79 on a process control book which shows you how to weld with minimal weld spatter and low smoke. 
  As to the "arc response". In good MIG equipment built during the last four decades, arc response times has never been an issue. Regards Ed


txtReplyBody:
Lous
     Use the standard weld symbol that denotes a butt lap or fillet and behind the feathers on the arrow stick EB

txtReplySubject:
RE: Weld symbol for electron beam weld - high vacuum (EBW-HV)?


txtReplyBody:
If it was all cast iron a high nickel rod  IF NOT TRY A stainless 312

txtReplySubject:
RE: welding oil pickup screen to oil pump


txtReplyBody:
Sorry for not being more specific about the oil pickup screen. The screen has mild steel tube that is pressed into the pump.It fits Chevy V8 race engines. If not welded to the pump,they will vibrate off. Is there a preference on electrode and gas? Thanks Again


txtReplyBody:
I believe you said you were going to TIG weld the parts. If its gtaw or smaw, the reason I recommend E312 WITH ARGON FOR gtaw is this wire is good on dissamiler metals, has a good ferrite level and there fore its got lower weld crack resitance. GTAW or SMAW give it a try, regards Ed


txtReplyBody:
Karl with high temp GTA welds there are minimal weld differences between most alloys excep aluminum. Focus on the pipe diameter and pipe weld technique required. Use carbon or stainless steel pipe and filler to practice . Good Luck Ed.


txtReplyBody:
I was in last week talking to my welding supply dealer on other problems.  Talk turned to your book and where I might purchase a copy and he loaned me his.  Morry Huber says hello.  He said you probably don't remember him from your days at Liquid Carbonic.


txtReplyBody:
Ernie I still didnt get you to buy a book, you must have some scotts blood flowing through your veins.  By the way FOR THE BOOKS look on this web site, home page, left top corner  under Ed's train resources, I remember your buddy give him my regards. All the best Ed


txtReplyBody:
Mike its likely one of four things.
[1] Your spray volts are set "too high' leaving  a long arc length which does not allow the arc plasma to remove the alum surface oxides.
[2] Not sufficient fore hand (push) angle, also needed to remove alum surface oxides.
[3] Material surface needs additional cleaning, 
[4] The  argon gas from your gas distributor is not as pure as you think it should be


txtReplyBody:
BY THE WAY MIKE THIS ANSWER COULD BE FOUND IN THE ALUM SECTION. ED


txtReplyBody:
There is another thing related to shielding gas. You didn't mention what flow rate you are using. I would probably start at 30-35 cfh. Too much flow can cause turbulance, drawing air in.


txtReplyBody:
Will there be any post weld cleanup necessary or will the weld look clean when finished?

- Mike


txtReplyBody:
a stainless wire brush is usually req Ed


txtReplyBody:
Steven with alum always use a min of 40 cuft/hr typical gas flow is 40 to 60 cuft/hr. Gas molecules assist in the cleaning action Ed


txtReplyBody:
Just sharing personal experience Ed. It worked with the particular problem I had. The operator had tried more gas, and the problem got worse, turned it down and the problem went was corrected.


txtReplyBody:
Terry this is the reason a America is overflowing with Lawers. If you feel the equipment does not perform the way you believe it should, get your company president to write a letter suggesting that you are ready to sue. I am surprised in a way as this company does not have a poor reputation. Good Luck Ed

txtReplySubject:
RE: Hypertherm  Plasma Cutting Equipment Issues


txtReplyBody:
Eds Reply. Jeff you may not know but many years ago I was employed by Airgas to develop a MIG gas marketing program. I produced a no nonsense, honest gas marketing program that took the BS out of selling MIG gas mixes. The two part MIG gas mixes I developed were called SteelMix, Stainless Mix and AlumMix, (scroll down for more info). Now Airgas is going down the three part MIG gas mix road. After reading the information at this site, what does the Airgas marketing approach tell you? I have said so many times that the two component argon CO2 mixes will provide you with welds that meet any weld code requitrments. You picked a winner stay with it and spend less time talking to salesmen who is looking to attain gas buisness.

txtReplySubject:
Helium Tri mix for MIG steels? not in my weld world


txtReplyBody:
kevin I HAVE POSTED YOUR QUESTION AND MY REPLY IN THE MIG GAS SECTION OF THIS SITR

txtReplySubject:
RE: Metal Cored wires and argon - 5% oxygen


txtReplyBody:
Todd, this is the place to get straight answers to this kind of question.  (cope)


txtReplyBody:
With an 035 wire you can produce stable short circuit with CO2, the differnce between the CO2 and the 75/25 co2 is 
[2] The stable, spatter free short circuit parameter range (wire feed) with 75/25 is wider.
[2] The 75/25 mix requires lower weld voltages especially important TO MINIMIZE WELD BURN THROUGH POTENTIAL when welding thin gage tubes.
[3] The Logical gas choice would be argon with 20 co2 then you can produce both short circuit and spray.
 CO2 cannot produce spray its a globular spatter mess.

 The bottom nine yes you pay less for CO2 however you are likey to use lower wire feed settings prolonging the labor cost which is far more relevant than the cost of the gas.


txtReplyBody:
Porosity in a Lincoln wire well thats unusual. Dont use these fast freeze wires for large horizontal FILLET welds. If you want welds with less worm tracks or porosity, a superior wire for vert welds is the Alloy Rods Ultra Shield. Read the pipe and flux cored section as to the reasons not to use E71T-1 for large fillets in the flat or horizontl positions, need more info call me on my cell  843 298 2054  ed


txtReplyBody:
Yes, the only problem is that we are prepping for a contest and we have no choice. I guess I just need to know if those parameters sounded acceptable and what motion you suggest for a vert up weld.


txtReplyBody:
For vert weld up set the wire feeder around 260 ipm at 24 25 volts (wire feed 10 to 11 oclock) h 3/8 to 1/2 wire stick out. The wire to work distance, the tip of the wire should be as close as possible to the weld, adjust volts to set this arc length. If wire touches the weld spatter will occur, provide a slight increase in volts >1/2 to 1 volt up. if the arc length is too long the weld surface will be too fluid, decrease volts 1/2 to 1 volt. For a 3/8 Fillet i would use  3 stringer passes. put in 3/16 to 1/4 fillet first using a slight osscilation in weld center, then allow to cool and put on second pass one side of plate allow to cool and then the other pass on opposite side. For horizotal pass turn wire feed up to 500 ipm and at 27 to 30 volts use a fore hand technique and aagain three passes. tHE 3 PASSES WILL ensure full side wall fusion for the 3/8 fillets. My flux cored book contains this. ed


txtReplyBody:
Thanks, we will try that. We have 20 copies of your GMAW book and have been using it as a reference, I apparently need to order the FCAW books as well.


txtReplyBody:
Paul knock em out with the seminar. At this moment I am kind of tied up with clients. If I can make Detroit I will post it  here in the QA section. If I cannot make it I would appreciate it if you guys out there that will attend keep me up to date on what looks good and of course on the extensibe bells and whistles. all the best  Ed


txtReplyBody:
JP. The following may help.

  [1] Increase the post flow "gas time" by at least 30 seconds and cut the part to see if its a post gas time issue.

  [2] If it's not a post gas time issue and you know that purge gas should be able to get to the internal area of the tube weld, consider using helium. Helium has smaller gas molecules that are lighter than air, so this inert gas may give you better coverage.

  [3] Can you increase the weld speed or decrease the weld current both of which will reduce the potential for internal weld and part oxidation.

    Ed


txtReplyBody:
I have had the oppurtunity to work with the STT power source and must say that it was a waste of money.  We could have bought 3 simple, 2 adjustment power sources for the same price.  The STT will not give you any versatility and the support for weld settings is very poor.  Lincoln told me that you cannot spray weld with this power source.  Keep it simple.  Go with something that you can easily find info for, like this web site. Good Luck-Brian


txtReplyBody:
Attach a wire spool mount (available from Miller Linconc ect) on the robot arm behind the wire feed controd and use 30 - 60 lb reels Ed


txtReplyBody:
Brent,
 If you can describe the floppy in "computer jargon" I might be able to help.
 Is there no repair procedure for the drive?
d

txtReplySubject:
RE: Daihen C2 Controller Floppy Drive, Old Style?


txtReplyBody:
JC There are many weld consumables, processes and weld transfer modes. The bottom line, there is a logical method to look at an application and instantly select a weld process and consumable to attain optimum weld quality at the lowest possible weld costs. However this QA  section does not allow the room I require for the answers. The info you want is found in my 600 page "Management Engineers Guide to MIG" book. Happy reading. Ed

txtReplySubject:
RE: How to select a weld transfer mode, process or consumable?


txtReplyBody:
I spoke with Mr.Zue he states the welder has two settings 1ph for non-ferrous and 3ph for everything else. He said you can run it 1 ph if you wantt. He quoted me the welder @ about $14,500 I asked him to repeat it and he said the same number(this does not include the feeder or gun) I'm going to call again I hope i heard wrong.


txtReplyBody:
JAY Its taken mr three years to build this site,  spend a little time at the site and you will find all the answers you need. Ed


txtReplyBody:
I set a robot weld one time to weld 1" copper to 1/4 stainless. These parts were used as large electrodes. I used pulsed MIG with alum bronze wires and argon gas. The welds were fine and the current conductivity was acceptable. By the way if some one in the power (MIG BLINKERED) industry says you cannot use MIG it typically means you can use MIG.


txtReplyBody:
whipping takes the arc plasma away from the leading edge of the puddle. This technique reduces both root and side wall fusion. Use whipping only on welding gaps or very thin gage sheet metal subject to weld burn through issues. Any weld shop that condones the whipping  practise is a weld shop waiting for a failed weld law suit . Ed


txtReplyBody:
Is it applicable for Thai welding engineer that certified with IIW


txtReplyBody:
For hobby type welds on a variety of metals I would get a small AC DC TIG welder Ed


txtReplyBody:
Matt, if you want a Mig, the 251 comes pretty highly rated by owners.  Check here for owner's viewpoints:
http://www.hobartwelders.com/mboard/


txtReplyBody:
This is not normal. If this filler metal is an issue change the wire mfg.

txtReplySubject:
RE: weld solidification of Inconel 625 GTAW welds.


txtReplyBody:
I would recommend the Licoln powermig 255. I just purchased one of these and so far so good. I have tried the smaller powermig 200 which miller has also an equivelent unit but it has a hard stepped style voltage control. You would be much happier with a continuously variable control.

Rich


txtReplyBody:
Everybody has their preferences, but you are the first person I have seen who prefers the infinite control over stepped taps. I have used both and much preferred taps.  Not too many machines offer them any more.


txtReplyBody:
I have had a 251 since January and I really like it.  I have used it on everything from fenders to 1/2" plate.  I also got the spoolgun for aluminum but have not had the opportunity to use this attachment yet, but I hope to soon.  It has taken me a while to get used to the digital readouts for wirespeed and voltage, but now that I am familiar with them, I can set the machine EXACTLY the same every time.  I have made charts of wirespeed/voltage settings from Ed's red book and post these on the wall to assist my sometimes por memory.  The digital readouts will display your actual speed and voltage for 5 seconds after you stop welding, which I use to fine-tune my settings.  

I am considering buying a small AC/DC tig welder for doing light stuff.


txtReplyBody:
Plastic is prefered to the traditional softer nylon that is typical The more rigid the plastic the better


txtReplyBody:
YOU need to find out what the finished properties of the roll have to be. Hardness - wearabily
etc, somes times  its logical to start out with a lower strength more ductile low current (less dilution)filler metal like E7OT-1 with pre heat - in the 400 to 500F range, and then surface with
the desired filler metal, do some researh on this one it could provide issues


txtReplyBody:
Anything is possible, try the weld institute web site in the UK they did extensive flash research, also try Edison as I believe they are affiliated with weld inst. This nay be a stupid question why do you want to flash weld these parts?


txtReplyBody:
I am glad I was able to help. You are using HIGH weld current and  multi-torch basic weld process technolgy to attain welds impossible with sophisticated electrobic bells and whistles. Well done. Ed


txtReplyBody:
It was actually quite a simple process that, in theory, should have worked and with a bit of luck, thankfully, actually proved to be quite a process. I'll take that kind of "Luck" as much as I can get it !
Thanks again !!


txtReplyBody:
We have high production rates for angle with odd length pieces. Flash welding has cut our scrap percentage down to less than 3% for several thousands of tons. I've done destructive tests and daily bends to verify perameters.


txtReplyBody:
ITS ALL ABOUT AVOIDING CONTAMINATION OF THE ROOT PASS, Neither stainless or carnon steel is compatable with an alum weld SO THE LOGICAL BACKING OF COURSE SHOULD BE ALUMINUM

txtReplySubject:
RE: Why Austenitic Stainless Steel Backing?


txtReplyBody:
Jack good question

  Ref the 3 part mix not only will it provide benefits it canadd to the arc instabilty. Oxy lowers the arc energy and the concern is it also lowers tthe required voltage. The higher the voltage the more stable the arc.

  Ref co2 content a 20 % co2 mix will provide superior arc stability than a 10 % co2 mix. The higher volts required by the 20 co2 will be beneficial for high speed welds or high deposition rate welds.


txtReplyBody:
Peter Here is the bottom line you should be using spray transfer with an 035 wire argon 10 co2 gas and if you have heat problems use the low end of spray with lowewr than norm spray volts. All info in my books. Ed


txtReplyBody:
Terasa once you learn my clock method you simply look at the wire feed control figure the weld dep; lets say 9 lb/hr figure the welder works 20 min/hr 3 lb/hr figure wire cost a dollar a pound and the gas cost $1 /hr. Your welder per hour cost $12 + over head $15 hr plus $3 for the wire a $1 for the gas = $31 divided by the pounds deposited = $10.33 cents per pound. Then you go into my site and figure that the brige you are building has 1000 feet of 1/4 fillet and a fillet takes 0.1 lb/ft thats how many pounds? are you getting the picture. I suugest my management and engineers book it deals with this subject


txtReplyBody:
due to its length I have posted this reply in the MIG Gas Section


txtReplyBody:
Dave its simply not practical or cost effective.

  To mix an argon 15- 20 co2 mix you would need two cylinders, (rent on 2 cylinders) you would have to purchase a mixer and the simple bottom line is a cylinder of argon would cost as much or possibly more than an argon co2  mix. ed


txtReplyBody:
[1] Silicon bronze SB will produce inferior weld strength to MIG steel wires on all coated and HS steels.
[2] Weld heat from steel MIG wires does not cause mechanical issues on HS stls when the welds are made with  short circuit.
 [3] If concerned about heat on HS stls note;  MIG short circuit stl welds will typically put in less weld heat than the higher arc energy pulsed process with SB wires.
[4] Costly SB wires are beneficial on bridging gaps and avoiding weld burn through, however this only applies when the parts are less than 1.1 mm.
[5]SB wires can readilly be welded with  short circuit, glob or spray. The only benefit from the costly pulsed equipment is "less spatter".
In the big three plants and their suppliers, SB and pulsed MIG is only used 
 [1] due to weld process ignorance,
 [2] because of aggresive salesmaanship
 [3] because of poorly designed parts, or     thin parts with excess gaps.

   Regards Ed

txtReplySubject:
RE: The use of pulsed MIG for auto brazing repairs


txtReplyBody:
Use the amp / wire feed relationship as described in my books. Ed

txtReplySubject:
RE: volts and amps rather than amps and feed speed?


txtReplyBody:
hmmm that was my point ... it has amps and volts rather than amps and feed speed. 

I presume it sets a particular voltage and then adjusts the feed speed automatically to obtain a particular current.

Anyway, I guess I've asked enough questions for free ... better go and buy the book ;)


txtReplyBody:
I too am trying to come up with a modular weld fixture for 3,4 and 6 foot wide boat docks, all 12' long.  I looked at the blueco ones and was quoted over $25k, not this time.  Let me know what you were thinking of and I may be interested.

- Mike


txtReplyBody:
Erik
     
  With argon > 15 co2, 035 steel wire requires over >210 amps for opt spray, you can get a  lower spray transition current if you use argon oxy. a five oxy mix will go  into spray > 180 amps. If you want spray with MIG you would haveto use an 030 MIG wire, you may also want to consider using an 035 E71T-1 gas shielded  flux cored wire from ESAB (ALLOY RODS ULTRA) With argon - 25% co2 and your small power source you could weld   any metal thickness with this wire in any position. All info in Eds  books. Good luck Ed


txtReplyBody:
Hi Mike,
If you'll send me a mailing address I'll send you some photos and a brief description 
of my work to this point.
David Fly
715-232-5041


txtReplyBody:
sounds like a "weld solification line". the lastr place to solidify is the center of the weld and this line is commom in both mig and tig welds


txtReplyBody:
Would this be considered a potential weld weak spot?  Have seen it more in wirefeed than tig. If a potential problem, would increased post flow help, extra gas keeping the weld area warmer, longer?


txtReplyBody:
if it is a weld solification line thats usually an indication of a controlled good weld.


txtReplyBody:
Wow, Robin, After reading your questions Ed's right... "better go buy the books".


txtReplyBody:
He is welding with globular transfer, poor penetration and lots of spatter, if he wants to weld vert down with the 045 he should be at the start of spray 350 -370 ipm with 24 to 26 volts, for horizontal fillets  370 - 500 ipm 27 29 volts  With the 035 wire vert down 500 ipm 24 - 26 volts,  horizonatal 600 opm 28  - 30 volts. The key to dealing with idiots is dont talk, show them.Ed


txtReplyBody:
This is the bottom line. Copper or none copper makes no difference. What makes a difference is the levels of alloys such as Siicon and managaese. How consistent is the wire chemistry? Is the cast and helix within the AWS wire specs? How well is the wire wound and packaged? How clean is the wire surface? In my visists to numerous plants  I have found that the none-copper coated wire from NS is an inferior product to a Cleveland produced copper coated L50 wire from Lincoln. I have evaluated MIG wires for three decades and have numerous technical reasons for this judgement, however they wont fit in the space allowed, feel free to call me on this subject. Ed

txtReplySubject:
RE: copper versus none copper coated MIG wire


txtReplyBody:
Today that question is easy to answer. If you can apply reasonable control to the root gap the Lincoln STT process is not only simple to use its very effective and faster than TIG or SMAW. If you cannot control gaps both SMAW and TIG, and for pipe under 4 inch diameter TIG is the logical choice.

txtReplySubject:
RE: best cost effective way to weld roots on pipe over 6 inch


txtReplyBody:
less wire feed issues
 lower weld costs
 higher weld deposition rates (faster speeds)

txtReplySubject:
RE: advantage of solid wire ER70s6 1MMdia over 0.8mm


txtReplyBody:
All things being equal, I think so.  I ran out of C-25 yesterday and switched to 90Ar/10CO2.  Had to raise the voltage quite a bit to get the same results


txtReplyBody:
Sir
Thank u for ur response. Can u pl elobarate advantage?. We will be highly greatfull to u.
TKS & REGDS.
raghunath


txtReplyBody:
if you only used argon to weld steel the reasons the bead is cold and covex should be in the gas section of this site Ed


txtReplyBody:
alan you dont raise the volts with a switch from a high energy gas mix to lower energy gas mix, a review  the gas section may help. ed


txtReplyBody:
its simple stick with ESAB or Lincoln E70S-3


txtReplyBody:
BARRY I DONT PROVIDE ANSWERS IF THEY ARE ALREADY IN MY BOOKS, OTHERWISE WHHATS THE POINT OF WRITING A BOOK. REGARDS ED

txtReplySubject:
RE: Horizontal 10mm fillet weld on robot.


txtReplyBody:
YOU ARE ASKING FOR TOO MUCH FREE INFORMATION.


txtReplyBody:
Using the clock method simplifies it. For eg you know that with an 035 wire set at 10 oclock, 210 ipm approx = 140 - 150 amps. Each turn of the 035 wire on the clock (70 ipm) will draw approx 25 to 35 amps with the 035 wire. With the 045 wire 10 oclock 180 - 190,  12 oclock 250 - 260 amps.


txtReplyBody:
You are in spray transfer, your current is fine make only adjustments to the voltage. Start out with the weld volts set too high, resulting in spray quite sound, lower volts  till crackle sound starts. Ed


txtReplyBody:
Fred,
Contact me and I'd be happy to discuss your welder/weld qualification issues.  
PWC
507-269-7142


txtReplyBody:
i would use the silicon bronze with gtaw


txtReplyBody:
you need to get past 200 amps and have a minimum of 26 27 volts regards ed


txtReplyBody:
Carl,
I use the Miller 250 In my Mig training course all the time.  We have no problem reaching the low end of spray with that machine.  90/10, 26v, 550 ipm, 0.035 dia.  The gun it comes with (M25)isn't nearly stout enough to run spray for long periods of time.
You'll like th equipment.
PWC


txtReplyBody:
Ed & Paul, thanks I needed the help. What I'm concerned about is 1/4-3/8 leg to 1/2 Pl & wanted to use 85/15 steelmix so I could short-arc & spray w/ one gas, but will the MM251 handle it ? Welds will be less than 2.5 min per 10 min . Thanks, Carl.


txtReplyBody:
using 035 wire the answer is yes one pass for the 1/4 fillet 3 passes for anything larger ed


txtReplyBody:
Ben try the following

 [a] if using an e70s-6 wire use an e70s-3 less fluidity.
 [b] If you use an argon 8 to 10 co2 you will also reduce the weld fluidity.
  [c] Try lowering the voltage ensure constant crackle.
  [d] Increase the push angle.regards Ed


txtReplyBody:
Michael I don't think it makes much difference what tool you use to input heat- the issue is thermal conductivity of Cu here, so even if you left it in hot summer sun to "preheat" before burning up your propane to reach the optimum temp, you'll still get to the working temperature your piece needs
d


txtReplyBody:
Ed, welding SS tube 14ga SS316L, both 10ft tubes and elbow gores. I take it we are discussing a 14 gage seam weld. There are three ways to weld this
[1] Short circ, 280 - 300IPM 15 - 16 VOLTS, 035 wire with argon 2 oxygen. square butt edges, weld vert down. Purge required
[2] pulsed VERT DOWN with same wire and gas,
[3] STT vert down with 045 wire same gas.


txtReplyBody:
Tried GMAW-P using 98Ar/2O2 and weld is very dark. Looks better 100 Ar.  What does 2% O2 bring to the table beside black welds?
Actually tested this on some 2205 super duplex. UT looks clean.


txtReplyBody:
the oxygen or co2 added to the argon brings arc stability, through more surface heat which increases the amount of cathode spots. As you are welding very thin gage you can use straight argon. Most of the oxidation that will result is causd through the atmospheric reaction of the hot weld. ed


txtReplyBody:
I sucseed to weld 6'' dia pipe, root pass , with NO gap (0) and with welding speed 0f 16''!!! BC current was 90, PC was 450 A and WFS was 170 IPM.
Butt weld angle was 70 DEG.and included angle on 2'o clock position is - 25 DEG (looking perpendicularity) 
BEST SALUTE from 


Vojislav
Best salute!


txtReplyBody:
Well, Ed I do not agree with You. Anyhow, I found that some SSFCAW wires are the most useful for specific application, than stick electrode and /or FCAW rutile wires e.g. for thick plate and vertical up welding. I sucseed to weld from 0.4'' to 1,5''root passes with up to 1/4'' root opening, in vertical up position using 270 A X-Butt Weld with sucsessfull x-rays and satisfactory mechanical properties on S355K2G3 steel (27J min on - 30 C). Application is with 0068'' SSFCAW wire NR-232 for oil reservoirs newbuilding.
If someone use FCAW, it must use ceramic backing,that increase costs, if it is stick electrode, productivity is more than half instead of NR-232.So, for semiautomatic welding, for specific application such is thick vertical-up welds, with x-preparation, an on the windy, open area, SSFCAW is better solution than FCAW or GMAW, or SMAW.


txtReplyBody:
I would try using the MIG short circuit process (035 70S-3 WIRE) wiith low weld parameters <160 AMPS 17-18V. Using 300 F for pre-heat, my welds would be stinger beads no longer than 25 mm. My interpass temp control would be 250F.  A procedure like this will have minimal carbon dilution into the weld and minimal impact on the casting.


txtReplyBody:
Ed I'am sorry it in Gas Meal Arc & Flux Cored Welding Parameters Thanks Jim


txtReplyBody:
I dont deal with self shielded as it's a lousy process not recommended for manufacturing, is there anything I can help you with?


txtReplyBody:
it sounds to me as if you are not getting weld fusion from that relatively cold 150 amps. This is a reqgular MG application (E70S-X) WIRES, however its no good worrying about the influence  of the weld on the materials if the weld is not fully fused. This application requires a minimum of 200 amps 21 - 22 VOLTS.


txtReplyBody:
Where in your ads that was for fcaw that it was dual shied and not selfshield wire? I beleive welding is done inside and outside. There should be date in this book for selfsheild wire!


txtReplyBody:
The first time i demonstrated MIG spray on a 0.100 stainless application the TIG welders could not belive it. The stainless TIG welders had tried short circuit on the 0.100 stainless but did not like the sluggish welds, I used 035 wire, WF 550 ipm, WITH 24 VOLTS USING AN ARGON 2 - 4 CO2 MIX. the 3/16 fillet looked as good as their TIG welds,  the difference was I welded 4 times faster. The bottom line is MIG can be used on numerous stainless applictions that at present use TIG, the only thing holding the MIG process back is MIG weld process ignorance. regards Ed


txtReplyBody:
use swage lock or TIG weld with filler

if you tig weld use 308 filler, purge the pipe with argon you should provide a weld joint to give you a complete penetration weld

txtReplySubject:
RE: TIG welding of high pressure stainless pipes, type 304


txtReplyBody:
Sorry, I posted this message by mistake. Please refer to my former posted message. Regards, Frank


txtReplyBody:
glen irrespective of the gas or wire you use you to attain a quality weld you are going to have to grind the zinc and perehaps put two weld passes Ed


txtReplyBody:
Its more to do with weld widths, the greatest benefit from the gas lens comes when you have to provide welds that are wider than 3 mm, the gas difusers are also beneficial for alum welds, the even distribution of gas is beneficial for any gas or gas mix. ed


txtReplyBody:
Good advise Ed! Been in the industry for a few years now and biggest problem I see with robotic welding and exhaust systems deals more so with joint location (not being able to stay on it). This is mainly do to part inconsistancy. We do use .045 cored wires with great success.


txtReplyBody:
Jack you have unfortunately ended up with a poor MIG power source. This power source does not allow the low normal weld voltage RANGE that is available from North American MIG equipment. The bottom line the short circuit weld voltage necessary with this equipment leaves you with a higher energy globular WELD transfer, (burn through and spatter) the solution is simple, buy American weld equipment.

txtReplySubject:
RE: Kobelco power source and weld burn through issues


txtReplyBody:
sounds loke hot cracking due to residual stresses. dont use large single pass welds allow innterpass temp of 300 f if problem continues try 312 stainless more ferrite less crack resisitance, good luck ed


txtReplyBody:
polish surface with ooo, use one part nitric two parts water. the etch it typically takes five to ten minutes, then wash with water


txtReplyBody:
Worm tracks are typical on a number of the fcaw wires, no only Lincoln, when 75-25 gas is used. CO2 will eliminate it or Lincoln has wires with a H desigination.  The rep told me this was heated to remove hydrogen.


txtReplyBody:
We weld and etch HSLA automotive supports. We use a Nitric acid 20% V/V which is a 20% strength solution in water.The more polished the surface the better the weld boundary line.


txtReplyBody:
I built this site hoping that people would go to the various sections and read the data, or better still they may buy one of my books on process controls.
First you dont need to know weld current density, what would you do with it?
Second you dont use 25 co2


txtReplyBody:
Plenty of information in the pulsed fundametals section and also in the equipment section whre you will see a comparison of a pulsed versus none pulsed stainless fillet weld.


txtReplyBody:
Mike, gas lenses are great for welding on pipe, whether it be carbon steel or stainless steel (small or large bore).  We are a training centre for high pressure pipe welding and that is all we ever use (gas lenses).  For welding titanium, we use a large gas lense with a 3/4" (12-19mm) cup + trailing  shield.  It does an excellent job of the finished product.  We have the pipes X-rayed all the time and there are never any defects. dh


txtReplyBody:
you are correct about run in rate and the weld gas is in percentage, (the distributor would fill by weight). I dont believe it makes sense to pay rent for two cylinder when you can buy a correct pre=mix, regards ed


txtReplyBody:
Jackson, your number one issue will be burn through, use a low energy gas mix for your short circuit application. An argon oxygen or argon <10 CO2 will allow the use of lower short circ volltage. Good Luck ED


txtReplyBody:
use a 7018 or if MIG  areg 79s-3 or 70s-6


txtReplyBody:
Ed, et.al., does the lead in the equation make the weld more likely to hot crack, or just put off dangerous fumes?


txtReplyBody:
Frank, this is a "standard" type of weld for us...as Ed stated, purge with argon and use 308L rod, bevel both ends 37 degrees, and leave a slight gap at the root for 100% penetration.  I ran a quick calculation per ASME Section VIII, Div.1 Pressure Vessle Code...you are good to 1,000 psig @ 500 deg F if you are using 3/4" nom sch 40, SA-312 TP304 pipe - this is the "standard" welded seam pipe material in stainless.  Steve


txtReplyBody:
Your power source is fine, certainly no need for  pulsed on parts >3 mm You will get superior penetration from regular spray.


txtReplyBody:
Les
    Good outside  the box thinking.However I hope the customer remembers to switch the weld polararity back as soon as they need weld penetration. Whats good for the goose is not always good for the gander. Ed


txtReplyBody:
Tony,

Since you will be welding on >3mm, the only benefit would be the fact that you could use a larger spool of aluminum and not a spool gun with the Power Mig 300 and a Push/Pull set-up. It depends on your production needs.


txtReplyBody:
Mat go to the steel section and vist tool steels, you are likely better of using the recommended SMAW electrodes


txtReplyBody:
you have to improve the contact between the painted part and fixture, try a clamp with a sharp point.


txtReplyBody:
Jerry

   If you visit the steels section ang go to tool steels note the comments on pre heat and specially the interpass temp control, also the filler recommendations. Ed


txtReplyBody:
Hello Ed,  The die I welded on was a  hardened A-2 die. Now I believe they said that it was drawed down, I take this means it was tempered for a period of time to reduce stress. 

Does draw and temper mean the same thing?

Could I pre-heat die at a certain temp for a prolonged time to help in reducing stresses prior to welding?

Oh yeh I have recently ordered some 312 rod.

Thanks Ed


txtReplyBody:
I was going to publish a book untill the publisher did a survey and they found out that only five percent of the weld profession can read. Thanks for the kind thoughts I am glad some one out there has my sense of humor


txtReplyBody:
argon - 5 % co2 or 2% oxy for 400 series

argon - 3-4% co2 or argon oxy for 300 series, if 300 series to steel the 5% co2 ok


txtReplyBody:
There are many portable gas analizers available that will tell youi the amount of the reactive gas that is being delivered to your MIG guns.

 I used to tell my gas supplier to come to our plant once a year and bring their portable gas analizer to do a chek of the gases. If the supplier wants your gas buisness they typically will do this for free. Certain hoses are poor for gas delivery use hoses recomended for argon mixes. Leaks will effect the gas composition they are are easily traced with with soap and water. Spray transfer, voltage fluctuations and coloration (oxidation) provide a clue something is happening with the gas, but be aware that MIG wire chemistry inconsistency and erratic weld transfer from that electronic powwr source are much more a likely cause your erratic arc symptonssystem


txtReplyBody:
I forgot to tell you also keep a cly of your gas available and when you believe you have  a bulk gas issue switch over to the cyl in the weld cell that is the greatest distance from the bulk tank and see if it resolves your weld issue. ed


txtReplyBody:
The subject is covered in the pipe and flux cored section of this site and in my MIG / FLUX CORED BOOK. The bottom line its likely moisture that has got into the flux. This is a common problem especially with Lincoln flux cored wires. By the way who is the wire manufacturer? 

The moisture can get into the flux due to poor wire manufacturing 
(poor wire joint seal), 
poor wire storage, (humid or damp location), 
no protection for the wire when its on the welder.  

 Take note of the wires storage and baking recommendations. Baking the wire before use sometimes helps, using a slightly longer wire stick out pre heats the wire, use the highest possible weld current, slowing down weld travel and increasing the weld size all may help. Dont use all position wires for horizontal flat fillets, fast freeze slag.


txtReplyBody:
By the way type in the word worm track in the search part of this QA and more data available. Worm tracks are moisture or hydro carbons think of them as an extended line of porosity rising up through the weld trying to get into the slag but the fast freeze all position slag solifies trapping the worm tracks (gas pores) in the weld
Many companies use all position wires for welds made in the flat / horizontal positions, they should use the EX0T-X wires which have a basic slower cooling thicker slag. Also these wires have more deoxidizers.


txtReplyBody:
Turn down the voltage. Keep the WFS the same just run a lower voltage. This solves nearly all worm tracj issues.


txtReplyBody:
sorry dan you have got it backwards, it takes energy to remove work tracks and decreasing voltage is not adding energy. By the way if your flux cored voltage was set correct turning it down even one volt would set up a bad spatter condition, Ed


txtReplyBody:
Dan  if you get worm tracks and you make a change in your case the wrong parameter change, and the sprodic  problem goes away, you may feel what you did rectified the problem. Of course a voltage change will influence a weld but lowering the voltage is not the answer to the issue. By the way I spent over two hundred hours  working on the worm track solutions at the the Tri Mark flux cored manufacturing facility, evaluating what influences worm tracks and what weld solutions reduce worm tracks, just "experience talking" Regards Ed


txtReplyBody:
try an 040 tungsten at 15 to 30 amps and have a drink on me Ed


txtReplyBody:
i tried mixing a c8 tank and an argon tank.i mixed them thru a coelesing filter off a compressed air line.when the tank pressures were equivalent it work fine.when they tank pressures varied by a few hundred psi one woul run longer than the other on shut down.so when you started the arc the gas mix was off and therefore the arc stability. after a second or so it stabilized. bottom line poor arc starts.


txtReplyBody:
I find it interesting that you are going to be building boats,would they be driftboats.I always thought it would be great to build my own aluminum driftboat,since new ones are so expensive.I have a snap on ya212ia (systematics)230amp mig welder with a systematics spool gun.The welder also has dc tig ,but not ac.
                                   JIM


txtReplyBody:
My guess would be the weld will likely be ok however you destroy the case hardening either side of the weld


txtReplyBody:
i forgot to mention grind the location your are going to place the weld at, ed


txtReplyBody:
you got to hobart for the basics and when it comes to MIG you will be lucky if you get it

txtReplySubject:
RE: Hobart's new course in weld process controls for the non-welder


txtReplyBody:
I read you loud and clear Ed!!!
Btw, What do you think about Motoman robots?
I know you consider Genesis and Prodomax as the best 2 in North America so, I'm curious as to how you rate this one...

Respectfully,
SSBN727 Run Silent... Run Deep!!!


txtReplyBody:
Prodomax and Genesis are intergrators, they work with many robots and they offer the total engineering package necessary for complex applications. 

With robots there are minor differeces that seperate the robots, I work with all robot brands I dislike working with Japanese robots however as my buisness deals with fixing problems, its usually a Japanese robot or power source that is the cause. ABB leads in both robot technology and robot expertise. What you need to be careful of is the MIG power source attahed to the robot. The bottom line if THE POWER SOURCE was manufactured  in Japan during the last decade its inferior to what you could have attained for half the price in North America.


txtReplyBody:
I never said it was "THE" answer but possibly "A" answer. touchy touchy


txtReplyBody:
Dan you cant get the bull out of this welding buisness till you get all the cows out of the field. I just dont want the information on this site to sound like its coming from the AWS site or from a lincoln salesman


txtReplyBody:
the Lincoln Power mig worked fine as a standard single phase power source no better or worse than many cheaper single phase equipment, cannot help you with the esab single phase. v

txtReplySubject:
RE: Esab welder in 'equipment evaluation'


txtReplyBody:
Thanks Ed, do not want to pay for synergic/multi-process/pulse on pulse, but the siren song of 300amps @60%,is loud indeed for this 'garage' welder,limited to single phase power supplies. Knowing that you really dont care for these questions, but have you done anything with Lincolns Invertec 350 Inverter? Besides kick it I mean ?


txtReplyBody:
Ray as you say I have minimal interest in garage welders, by the way who do you work for, you sound like a distributor sales rep.


txtReplyBody:
Ray weldcome to my world, i am glad to see you could pick out the difference between equipment manufactures MIG weld recommendations and weld reality. Sorry about the sales insult but you did sound like a weld sales brochure. Regards and keep reading. Ed


txtReplyBody:
my clock method provides all this data, in any of my books, Ed


txtReplyBody:
That pulsd TIG (MIG) appearence (low pulsed rate) may be fine on thin alum, however it may also cause lack of fusion on specific parts. Are you having issues spray welding the 0.090. Pulsed MIG on alum is beneficial on parts <0.090 . With your alum gage pulse or spray is fine,


txtReplyBody:
you have a 10 switch starting at 15 volts finishing at 30 volts so i assume the inncrements are approx 1.5 volts for your short circuiit settings.
 [1] with 035 wire. Wire feed 10 o'clock, first or second increment 16.5 to 18 volts.  [2 wire feed setting 12 o'clock use the third setting.  setting 19.5 volts, for a sprray setting you need an 030 wire open up the wire feed 4 o'clock and start at the 7 volt tap. with these volt settings listen to the arc then make asjustments to the crackle sound produced, ed


txtReplyBody:
so the same would apply if i did not have a switch voltage setting ?
and i really need spray transfer to be able to weld .188" steel i would not be able to do it using short circuit
and i can use .030 wire for spray transfer is it not  pushing the limits of the wire ?

the settings on my machine recomended by miller are 385 ipm for wire and 22 arc volt this sounds a litle hot


txtReplyBody:
I have never had welding problems using short circuit or spray on glvanized. Weld it just the same as you would with none coated steels except  try to increase the weld energy to assist in reducing the internal weld contaminates. Use 035 e70s-3 with 80 argon 20 co2 for your short circuit and spray applications. When welding use short wire stickouts  3/8 - 1/2, make sure fillet welds are convex rather than concave. Use slower weld speeds to increase the weld freeze times. Your contamination content will depend on the galvanized coat thickness and the bottom line when you weld on crap its alway part of the weld, therefore be more concerned with weld fusion profile than weld porosity. Use galvanized in the key word search for more info

txtReplySubject:
RE: Information on welding galvanneal and galvanized sheet steel


txtReplyBody:
for aluminum yes, waste of time and money for steels, ed


txtReplyBody:
Its a pity that more instucters who work at the community colleges dont visit this site. With your power souurce i would use an 035 wire and straight CO2 FOR UP TO 3/16 STEELS, FOR STAINLESS AN ARGON 2 OXY MIX. THE ARGON OXY MIX COULD THEN BE USED FOR SPRAY TRANSFER ON STEELS WITH AN 030 WIRE. READ THE MIG GAS SECTION AT THIS SITE FOR EXTENSIVE GAS DATA, GOOD LUCK ED.


txtReplyBody:
what process are you using (GMAW or FCAW) and if you're using a shielding gas - what type?
Finally, what diameter wire are you using?
Respectfully,
SSBN727  Run Silent... Run Deep!!!


txtReplyBody:
you need an035 wire argon oxy mix and setat 9 oclock weld vert down 14  15 volts.


txtReplyBody:
use the same alloys, or alum bronze to weld all three, use argon, REP, short circuit, spray or pulsed,use the wire feed settings in my books and the voltage settings in my books minus 2 or 3

txtReplySubject:
RE: Info on welding of Copper, Bronze & Brass


txtReplyBody:
Bob your through the arc tracking is looking for small arc voltage variations which from a traditional CV power source with a fixed wire stick out would typically be minimal. With the Lincoln PowerWave you may be getting inconsistnt weld voltage. On one Power Wave I recently checked the weld volts variation was just over two volts and the weld current variation was over 100 amps. This parameter swing was  on a 1/4 fillet weld three inches long, with constant wire stick out of 1/2. Check your power source if the weld parameters are not stable you know what to do, regards Ed

txtReplySubject:
RE: robots and  through arc weld joint tracking


txtReplyBody:
as long as the power source is stored in a dry location it should last for years, as for the MIG wire if its steel give it time and it will rust


txtReplyBody:
The strength of the weld is the strength of the weld wire. Be less concerned with the shear strength and more concerned with attaining a  full penetration weld,


txtReplyBody:
I was just wondering what model Powerwave you are having problems with?


txtReplyBody:
If you use an argon purge and tig weld why worry abot the interior weld?


txtReplyBody:
TIG in the field yes, anyting to do with the food industry should be a none slag process, you would simply provide a tent like structure to cover the welds. Treat this eld the same as you would in the shop


txtReplyBody:
you can buy one from Lincoln for $600 or purchase a "jaquet speed indicator", use google as web search i saw one for $80


txtReplyBody:
No, Ar cant be used for all processes.  Straight Ar is for aluminum.  Ar Co2 mix for mild steel.  You can also use straight co2 for mild steel. HTH


txtReplyBody:
you can weld most steels with with tig the bottom line is will you use sufficient pre-heat, then you have to consider  interpass temp and  post heat controls. What condition is the cast? is it impregnated with contaminates that will influence the weld quality?. Then give consideration to what you want from that weld in terms of strength ductility  hardness or corrosion properties.  Doing  the cast weld in is the easy part addresing the cast issues is the part that you may want to give more consideration to, reegards ed


txtReplyBody:
I have found that increasing stick out helps with worm tracking.  Just for kicks if you have a slip on gas nozzle, try recessing the tip about a 1/4" then try to weld.  MIG welders usually hate doing this but I have found it to work.  (You are incresing amperage thus increasing energy at the arc by doing this)


txtReplyBody:
Tim you have a case of Premature Japanese Robot Communication Itis. Instead of the robot going to the end of the weld and instantly bringing up the weld end / crater fill data, your robots which have obvious robot / power source interface timing issues are a little premature. I know how to get around this common Japanese issue (you can call me) hower your complaint should be with Fanuc and Motorman.


txtReplyBody:
if you want higher strength and improved weldability and more ductility consider  5183 first choice  5356 second choice. If you want greater resistance to corrosion in salt water use 4043, BUT REMEMBER YOU WILL HAVE LOWER STRENGTH AND DUCTILITY. dont bother with an argon helium mix unless welding alum > 3/8,  and an argon - 40 to 50% helium is much more logical than the 90% helium mix they used to recommend.


txtReplyBody:
Would you use just a straight Argon then or a Argon CO2 mix?
Thanks,
Andrew


txtReplyBody:
sorry jim no experience with this one, regards ed


txtReplyBody:
the E70S-3 was designed for use with argon mixes, the E70S-6 wire was designed for use with straight CO2, E70S-3 is the better choice for most argon mix applications. GO TO THE MIG EQUIPMENT AND CONSUMABLE section of this web site its all there regards ed


txtReplyBody:
you are welcome, good process data can make any bad powersource look good, ed


txtReplyBody:
you did not say where the cracks occured in the  welds, haz or?

 YES YOUR  FIRST CHOICE SHOULD BE GAS SHIELDED FLUX CORED.


txtReplyBody:
brad the weld procedure looks good. I would hope the interpass temp is the max rather than the min and also I hope you are minimizing weaves and using stringers, if so the bottom line is it would appear to be a a weld consumable issue. Why
not try another BRAND of electrode wire, let me know the results, ed


txtReplyBody:
Jim, your comments, were in poor taste..
Many, myself included, see the state of the industry to be precisely as Mr. Craig has mentioned. I entered this industry in 1980 and as a 13 yr. member of the Society, I too have found the display floor of the Expo to be of little value. I struggled to spend 45 min "on the floor.

My suggestion to you would be to spend more time at www.weldreality.com. and less time looking at Pixy Dust, read, you may learn something.
Regards,
Paul W. Cameron
Weld Engineer
Crenlo LLC - Rochester, MN
507) 292-6163


txtReplyBody:
section the welds and ensure the data used provides sufficient side wall and root fusion. PARTS LESS 3/16 YOU SHOULD BE ABLE TO SEE THE FUSION WITHOUT ACID ETCH, PARTS > 3/16 USE ACID ETCHOVE. How often you do this test is how confident you are on maintaining weld process controls. Remember when you look for weld issues  with the mig process you are sure to find them. TRAIN THE PERSONNEL INVOLVED ON HOW TO REACT TO THOSE ISSUES. ED


txtReplyBody:
matt i have not scheduled another one,WOULD YOU LIKE A SESSION AT YOUR FACILTY? IF SO CALL ME AT 828 658 3574


txtReplyBody:
with an 035 wire using the spray data in my books, no problems now no problems 30 years ago


txtReplyBody:
bob for gods sake this is not a repair shop, you could have 20 different problems as to why you dont get power output,

txtReplySubject:
RE: SnapOn Blue Point (Systematics?) YA5550A plasma cutter


txtReplyBody:
I should have mentioned that one of the guys comimhg to the workshop is coming from western austrailia he has  5000 miles to go before he leaves Sydney for the usa, that one hour flight from cicinatti to denver is not  so bad,


txtReplyBody:
Your right, it dosen't sound so bad compared to that!!


txtReplyBody:
brian there is a reason this site is calld "weld reality" buy a new bar.


txtReplyBody:
all my books not only provide this data they simplify it, visit  ed'd train materials

txtReplySubject:
RE: formula for amount of weld wire required?


txtReplyBody:
I am currently working as a weld technician in an automotive factory in western Ky. I am interested in your posting. If you are still looking for an experienced weld technician please e-mail me at joyous@charter.net


txtReplyBody:
bob try AC electrodes and search the web for de-magnetizing equipment, regards ed


txtReplyBody:
Andrew,
  I asked the same question on the AWS board and also here on here is what Ed had response was to my question. I still see the whipping action when we bring in new welders and at times it can be a hrad habit for them to break.   
    Brett B.

____________________

whipping takes the arc plasma away from the leading edge of the puddle. This technique reduces both root and side wall fusion. Use whipping only on welding gaps or very thin gage sheet metal subject to weld burn through issues. Any weld shop that condones the whipping practise is a weld shop waiting for a failed weld law suit . Ed

txtReplySubject:
RE: To weave or not to weave, that is the question...


txtReplyBody:
Weaves with robots are ok as they are consistent and the osscilation speed is such that the weaves can improve side wall fusion on horizontal fillets. On fillet welds up to 1/4 manual weaves should be discouraged, on 5/16 horizontal fillet welds a slight osscillation rather than a weave will get the job done. On fillet welds in the flat position weave or no weave the weld will get where it needs to go.


txtReplyBody:
I appreciate it. We do mostly sheet metal in the 20 to 11 gage range. So I will just try to get them to minimize it. Their issue with it is mostly visual, if they dont oscillate the weld doesn't look as controlled to them.

Thanks again,
Andrew


txtReplyBody:
If you can use torch movement to reduce weld burnthrough potential on gage its justified, its the weld fusion potential with fillet welds > 0.150 thats the concern


txtReplyBody:
GLAD TO HELP ON THE MIG SPOT WELDS. AS I HAVE SAID ON THIS WEB SITE AT LEAST A MILLION TIMES, WELDING IS NOT ABOUT BELLS OR WHISTLES ITS ABOUT APPLYING PROCESS EXPERTISE AND CONTROLS TO WELD APPLICATIONS. ED

txtReplySubject:
RE: Thanks for the MIG spotweld information...


txtReplyBody:
I integrated a robotic welding job that had some magnetism issues - mig welding steel...using an AutoInvision II.  We tried a bunch of things to try to work around it, even tried some archaic ways of demagnitizing...we ended up doing double passes in the areas where we had severe arc blow...it seemed to work.  Magnetism on this particular tooling seemed to be started by the final grinding process on some of the tool steel components.  The DC current made it worse from there...  The joints that had arc blow actually had no weld in them at the end of a pass, so we programmed the robot to loop through those areas twice.  It always worked on the second try.

Weird stuff and hard to get rid of.

Ed - excellent site - I reference it a lot!


txtReplyBody:
The bottom line as long as the weld has sufficient  energy to penetrate and you don’t make the weld too hot there is a good chance that the weld will solidify without a crack, after all a lot of welders have the shakes when they weld especially after a night at the pub. To optimize the weld quality make sure no millscale or surface contaminates and do a dye pen or ultra sound after the weld.


txtReplyBody:
you have to have penetration otherwise its not a weld. I can understand reducing weld pen to minimize weld fusion to lessen the weld heat impact on the high strength armor plate, but globular will get you in trouble, use spray transfer and increase your weld speed to minimize weld fusion, ed


txtReplyBody:
sorry for delay andrew i am travelling, the corrosion potential will improve but the weld solidification will slow down making the weld a little more sluggish which you may or may not notice


txtReplyBody:
I BELIEVE IF YOU LOOK IN THE APPROPRITE SECTIONS ON THIS SITE YOU WILL FIND THE ANSWERS. ED


txtReplyBody:
Its a global epidemic, but the process controls solutions are available at this site


txtReplyBody:
Always nice to hear from you vastly superior and erudite people.


txtReplyBody:
the aws books i value are the structural code the filler metal specs, and relevant weld fume specs. I help write the aws MIG gas spec but its a waste of time. Ed


txtReplyBody:
Thanks Ed,
I always appreciate your input.

Andrew


txtReplyBody:
The power wave has a pre established crater fill weld schedule in your pulsed programs. When you are in the spray mode you will have to put in a seperate crater fill weld schedule for the craters. Regards Ed


txtReplyBody:
As mentioned in the flux cored section of this site there are many unique attributes to gas shielded flux cored, as the weld decision maker you attache the attribute or benefit to your application. If there are no safety, cost, quality or productivity benefits, there is no justification,

txtReplySubject:
RE: E81T1-1 FCAW Consumible is better than Solid MIG wire ER80S-Ni1


txtReplyBody:
I dont know whats causing your problem but to identify the problem establish a  TCP and check  before welding. To compensate try 
[a]weld weaves 
[b] I dont suppose you have through the arc tracking?
[c]add more points
[d]use linear moves.
Let me know the cause when you find out regards ed


txtReplyBody:
its more sluggish than 308 The 316 has more alloys improving corrosion resistance and high temp service, so the bottom line is the 316 cost more, provides properties you dont need and increases the weld sluggish potential,

txtReplySubject:
RE: Is there any advantage to using 316L to weld 304 to 304?


txtReplyBody:
jason

     Before you try pulsed MIG on that high nickel application give Stoody a call and try their all position gas shielded flux cored wires. In contrast to the pulsed MIG you should  double your weld deposition rates, provide superior weld fusion, and these wires will also  require less skill than pulsed MIG, good luck Ed

txtReplySubject:
RE: pulsed welding on high nickel steels


txtReplyBody:
steve you have to let me know the 300 or 400 series types / grades ed


txtReplyBody:
Ed,
My online research indicates that most of the exhaust systems are 409.  I have found special .045 cored systems, but I am looking for something I can get in a small quantity.  I read that 309 can be used for this application and I am leaning in this direction.  I just need to make a few welds on an exhaust system.  Most just use plain steel wire.


txtReplyBody:
I will let you know as soon as I find out. I talked to Panasonic and they suggested using a program that moves all the axes and pushes two dial indicators a prescribed amount with a loop program that runs for 45 minutes to check for any movement or variation.
They thought that if there is movement it may either be the encoders, adding an extra pulse, or the harmonics may be bad. 
I will let you know what I find.

Thanks,

Andrew


txtReplyBody:
ITS SIMPLE. I WOULD ASK THE DESIGN ENGINEER TO SHOW ME HOW TO MAKE THIS WELD AND WHEN HE FAILS I WOULD ADVICE HE READS MY MANAGEMENT AND ENGINEERS GUIDE TO MIG OR GET A WELD PROCESS EDUCaTTION. Regards Ed


txtReplyBody:
Most likely the best results will come from nickel based flux cored wires try Postle Industries they make the wires and will provide the heat treat, regards ed


txtReplyBody:
I would try an alum bronze wire on a sample part then take it over to the vice and bash the hell out of it with a hammer


txtReplyBody:
I suspect that the size of the multipass welds might be causing the cracking.  Undersized welds and concave welds on thick or highly restrained components can lead to hot centerline cracking.  Since the center of a weld solidifes last, cracks can occur in the center that will be pulled open by internal stresses, this is a condition called hot cracking.  Three  ways to overcome hot cracking: increase weld size, make weld more convex or preheat the joint to 200 F.  Also, to lower your costs, you should consider using a larger electrode, or switch to gas-metal- or flux-cored-arc welding for this application.


txtReplyBody:
Build up a 25 mm fillet weld in multi passes each pass 1/4. regards ed


txtReplyBody:
it depends on what your code, procedure and qualification requirements are, if no restrictions spray transfer overhaed in small increments is easy to control especially with 035 Wires and argon 5- 10 CO2, however if you had pulsed this would reduce the energy and give you more control


txtReplyBody:
go to the application section of this site the info is there on this SC process


txtReplyBody:
I don't have one about a WPS, but I do a story about a WRP.  I showed up on site and was asked to sign off on a repair.  When I asked to see the "validated through testing" Welding Repair Procedure Specification, the response was, "It's a 40mm weld".  This was repeated to me several times during my insistance to see proper documentation to avoid legal rammifications.  When I stated that that was a specific of the spec, but not the entire spec....the glazed look and immediate defensiveness reared their ugly head.  Then I got the classic "I've been welding for 30 years blah blah blah blah blah..."  Who can guess what industry I work for?


txtReplyBody:
I simply dont have time for these products, if you use the right weld equipment, the optimum weld consumables, set the right data and implement effective weld process controls you will have few issues, Your managers need to get their focus on the root cause of the welding issues, ed

txtReplySubject:
RE: Weld Print Online Fault Detections System for Automated Welding


txtReplyBody:
To the person who sent this email, your email address did not work. 
To minimize suck back ensure the parameters you are using with the 045 wire, are aprox. Peak 360 amps, Back Ground 60 amps, wire feed 140 ipm. If you slightly reduce the root gap or slightly increase the land, and minimize the weld weave (this thins out the weld) you should be allright. Ed


txtReplyBody:
Raul,
There are two main things to check on the robot but they are different depending on which robot you are using.  
First, you may have lost your Arc Response Signal from the welder back to the robot.  If you are actually striking an Arc but get alarm after 3 seconds, the problem is either in the welder or in the Robots welding PC card.  
If the robot tries to strike the arc but the alarm occurs instantly, and no weld arc is generated, the problem may simply be a setup issue in the robot.  In the case of Fanuc or Motoman, there is an Arc Fail timer that could be set to 0 sec.  Robot will alarm instantly with no arc. 
Finally check your torch and ground cables.  An open circuit in the weld system will prevent arc striking.


txtReplyBody:
If its a cladd application you want minimum weld fusion. minimum weld dilution. At the end of the day clad weldsd or just plain welds the flux cored process if set correctly should be superior.


txtReplyBody:
Thank you, i found the problem my negative(-)voltage sensing lead was open rigth at the my welding power source conection,


txtReplyBody:
Frank the following will reduce porosity (hydrogen) typically found in alum welds. By the way its fine to be concerned with the porosity dont forget to also focus on the sidewall weld fusion.

  [1] Use a slight osscilation of the alum weld puddle while welding. Puddle agitation typically results in less weld porosity.
  [2] Use the lowest possible weld voLtage, a short arc length means a more concentrated mig plasma, more plasma energy means less porosity.

  [3] Try to use the largest possible gas cup and see if a diffuser for your gun is available.

  [4] Apart from the normal cleaning solvents and practices recommeded for cleaning alum, just before welding use a stainles wire wheel.

  [5] Try an increase in the push or forward angle.

  [6]Increase the arc energy through parameters, slowing down travel rates.

  [7] Use 60 argon 40 helium gas mix.

                     Good luck Ed

txtReplySubject:
RE: Reduce porosity in a spray alum weld


txtReplyBody:
Terry check out the helmet lens they are welding with, 10 for spray or pulsed and the next lighter shade for short circuit. If that doed not work get them a seeing eye dog, regards ed


txtReplyBody:
I would pre-qualify the parts with MIG and only use pre heat if the parts showed evidence of moisture  regards ed


txtReplyBody:
Tim I would rather not weld than use an 030 wire for alum. The smallest alum wire I want to use is the 046. 
[1] If using a regular MIG gun it should be no longer than 10 feet, 
[2] make sure you have a plastic / nylon liner for that 046 wire. 
[3] Check the alignment of the rolls groove with the guides. Make sure the rolls are for alum. 
[4] The  guides should also have a plastic or nylon liners. 
[5]If you go to the alum section of this site the wire feeds and voltage for alum spray transfer are spelled out. Run the weld wire for ten sec's to see that you have set the opt recommended wire feed setting. 
[7] If using pulsed set a low spray wire feed setting then adjust the voltage. 
[8] At the start of your weld make sure the wire is cut back to the nozzle. 
[9] Use fore hand (push) 
[100 Set the weld voltage setting typically 22 - 24 volts. The volt setting produce a consistent crackle sound, 

Good luck ed. Ps. If you read my books you would no longer be a newbe


txtReplyBody:
Why not invest in autodarkening helmets, even starting with just one.  Obviously they will still be working through the darkened lense, but it is so much easier to keep track overall, I can't imagine them wanting to use the soapstone.


txtReplyBody:
Bottom line. The T-11 as indicated in the flux cored section of this site, section 2 is a self shielded wire that will not provide the quality of a gas shielded flux cored wire or the quality of a spray MIG weld. THE SELF SHIELDED WIRE WILL ALSO NOT PRODUCE THE WELD DEPOSITION RATES ATTAINED BY MIG SPRAY AND OUT OF POPSITION GAS SHIELDED FCAW. 

If you can use MIG spray its first quality , cost choice, if you need to weld out of position use the gas shielded 045 OR 052 71T-1 flux cored wire, my first choice for the flux cored gas shielded wire would be alloy rods or tri mark.

.


txtReplyBody:
Also, consider getting them "cheater" lenses for their hoods (Magnifies 1x, 1.5x, 2x...).  If they need glasses to read, they need glasses to weld.
PWC


txtReplyBody:
ANDREW AFTER THE GAS-MISINFORMATION YOU SHOULD HAVE REALIZED YOU WERE TALKING WOTH A SALES IDIOT.  I AM PRETTY SURE I COVERED METAL CORED UNDER MY FLUX CORED SECTION, BOTTOM LINE IS THERE ARE NO DEPOSITION RATE ADVANTAGES, JUST KEEP DOOING WHAT YOU ARE DOING, REGARDS ED


txtReplyBody:
Iam currently using lincoln  super arc l-56 wire and leep getting complaints that the wire keeps getting hung in the tips, any suggestions


txtReplyBody:
Yes i have done it in great detail, however its in the design for welding section my robot process control workshop, its  available in CD format for about half the price of a useless pulsed power source.

txtReplySubject:
RE: Robotic Constraints on Dimensional Deviation with Stampings


txtReplyBody:
I'll gladly pay you tomorrow for information you can give today!  Just jokes.  I'll be contacting you to purchase the workshop.  It appears to be the only thing that can save my company at this point.  We have a ton of meetings, but nothing ever gets better.  I guess none of us is as dumb as all of us!


txtReplyBody:
nthony. I visited the Zena site, it looks interesting I am sure like mos generators it welds OK. My concern would be reliability, I would hope its not made in China, Maybe some of the participants at this site have experience, regards ed


txtReplyBody:
No and the use of low parameters WITH THE GAS SHIELDED FLUX CORED WIRES will result in lack of fusion and slag entrapment


txtReplyBody:
i do not recommend down hill on parts over 3/16 as lack of side wall weld fusion typically occurs


txtReplyBody:
the training book deals with the process technical requirements specifically for mig manual and robot process control, the management book deals with just about everything to do with both the mig and flux cored process with a whole section dedicated to the management mind set of establishing effective robot weld process controls.


txtReplyBody:
To back up what Ed says, I've done many, many, many... PQR down hill and found only failed tests.  I've been pushed to approve this (down hill on material >5mm) and have never been able to successfully do it (I'm sure they are at the point of seriously questioning my welding ability).  This issue comes up (in my company) about every 6-9 months.  Most recently a group of 4 Managers just returned from one of our competitors in Europe (not a welder in the bunch).  I was called into a meeting after they returned and told that our competitors are Mig welding 10mm plate straight vertical down.  "What are the obstacles that stop us from doing the same?"  I could only respond... "Me."  PWC


txtReplyBody:
Thanks guys, great information & very appreciated.


txtReplyBody:
Sounds like an intresting situation the only problem I have with it is with a regular CV power source you can set 100 cfm or have no gas and still get consistent arc starts. Possibly the Panasonic power source has a steeper slope and there is less current available at the arc start. With limited curent and no gas ionization benefits from an established arc you end up with inconsistent arc starts, o well its just another reason why you dont waste money on a panasonic power source.


txtReplyBody:
sorry not familer with this product, perhaps our weld team can assist


txtReplyBody:
When I set prototype, robot gage welds on parts <0.080 I will ensure the weld is not more than 70% to avoid weld burn through. Typically i want my gage weld PENETRATION to be in the  20 to 70% weld fusion range.


txtReplyBody:
The only saw blade mfg I a visited used a laser to cut the blades and the laser to work harden the edges. On other blades once the blade is cut brazing was  used to attach cutting components to the blade edges, regards ed


txtReplyBody:
550 ipm for an 035 wire is the optimum spray tranfer sweet spot for the wire, suited to steel parts > 0.080 You can actualy run the 035 at over 1000 ipm, HOWEVER once past 600 ipm its logical to switch to an 045 wire. I am thinking of writing a new book titled "Bullshit and the Last Salesman" regards ed


txtReplyBody:
I have heard nothing but good feedback on HTP.  If you have a problem I would contact HTP; Jeff the President takes customer service seriously.  The Mini-Mig gun is rated for 160 amps I believe.  The #1 would be a better choice for the 200.


txtReplyBody:
Peter this question is covered in the spray transfer section of the site. The mill scale composition found on most carbon steels does not cause major weld issues, however the scale can affect weld fusion and weld speed and weld porosity potential. On hot rolled steels over 1/4 the mill scale thickness will vary, in general the harder it is to grind the scale off, the greater the influence of the scale.


txtReplyBody:
just go to google and type in military specifications and you will find many sources.


txtReplyBody:
Dale after 18 years  writing the QA column in the Weld Design Fab mag, the new editor does not want the QA column any more as his key advertisers Miller and Lincoln object to my point of view on pulsed welding. The power of advertisng and salesmanship wins over free expession, which is typical for the weld industry. All the data you need on weld gas is found in the MIG section under weld gases, regards ed

txtReplySubject:
RE: low energy gas mix and Weld Design Fab magazine


txtReplyBody:
How can a scholarly publication like Weld Design and Fab take such a staunch and detrimental stance simply because their advertisers have no knowledge or factual basis to support their erroneous pulse theories?  The welding community as a whole will suffer from this revocation of common sense, and I urge others to contact the new editor and suggest that he take his hand out of the proverbial cookie jar; our welding arteries are clogged enough from the fat in our suppliers' "expert" suggestions and questionable sales tactics.


txtReplyBody:
Any recommendations on what type of shielding gas to use with this type of wire.  Also any recommendations on which manufacturer of wire to use.


txtReplyBody:
try the local weld distributors its available in rod form use straight argon


txtReplyBody:
Paul I would think that the majority of auto part suppliers ignore the weld changes that are made daily in their robot cells to compensate for part dimension deviations, the bottom  line is how effective are the weld changes and what tests are carried out to determine the resulting weld quality.


txtReplyBody:
As you cannot fine tune the voltage provide a small increase in wire feed and weld a little faster


txtReplyBody:
Ed,
I can fine tune the voltage, it's just that the scale doesn't read in volts.  Are you implying that the "popping" is caused by the wire going into the molten pool?  I am a beginner so bear with me.  Thanks.


txtReplyBody:
your wire position i beleieve is short circ, measure it for 10 secs you should have around 40 - 50 ipm for 10 secs if this so a plopping sound indicates the voltage is too high. When i said you cannot fine tune the volts I meant the incremental  volt control is likely around two volts per turn no half volt adjustment.

SO SHORT CIRCC PLOP SOUND VOLTS DOWN OR WIRE UP


txtReplyBody:
how thick is the part and why are you using the STT

txtReplySubject:
RE: Weld faults with Linncoln STT welding source


txtReplyBody:
045 wire spray 420 - 440 ipm I - 2 oclock 27 volts, 10 to 15 CO2


txtReplyBody:
it sounds like you are not breaking up the surface oxide, are you using AC? if so keep HF on.

txtReplySubject:
RE: impurity in shielding gas that causes black or dirty weld


txtReplyBody:
Mostly exhaust pipes for North America O. E. are 409. You should use 409 wire (either solid or metal core). 

Japanese cars use 304, you should use 308 or 309 wire.


txtReplyBody:
The thickness of the part is 18ga carbon steel. It is a miter weld that is joggled when the two parts are assembled before welding. We are using the STT welder because that is the one our integrator recommended with the cell. This was our first time using robots and welders together in our plant.


txtReplyBody:
Ed,
I forgot to ask 1 final question about this part.  Due to having to grind and polish the part after welding, it was also recommendd to us to Thermal Arc Spray the joint.  This would be to add coating to the parts before machining to avoid removing base metal.  Do you have any experience with Arc Spraying?  If so what do you have to say about it.  We did look into it but I think it would be best to avoid it if at all possible.

txtReplySubject:
RE: GMAW of Silicon Bronze for Class A Automotive Parts


txtReplyBody:
Can you dip coat or paint the parts after welding by the way are you not cncened about the much weaker weld joint you will get with this consumable?


txtReplyBody:
The parts will be painted after this process.  We are concerned with the much weaker joint that this produces, thus we are looking into alternative joining processes, say spot welding in certain areas for structural integrity, than filling any gaps left over with Silicon Bronze so we can machine down and produce a nice finish.  My question still remains; Which gas and power source will work best on this process based on your experience?


txtReplyBody:
the answer is under your question called silicon bronze


txtReplyBody:
Ed,
What about plate to tube using 2-12 stagger opposite side of tube with 1/4" fillets?
How do feel about plug welding? Cut holes in table top and plug weld to tube 13/16" dia hole 9" C-C grind flush?
Still spray and keep it flat to within +-1mm?
I will let you know results next week as we will test GMAW spray and FCAW


txtReplyBody:
Ed,  too hot for 4x4x1/4, melts tube away for single pass .045 GMAW welding....20volts, 325IPM, 15%Co2 single pass DH on the verts, flat on top and bottom looks good on the outside but I have fusion reservations, tube ID shows burn in. 1/2" wall tube can take more heat but will probably use FCAW on 1/2".

Can you personally really run that hot single pass on 4x41/4" square tube?


txtReplyBody:
IN most flow meters the pressure is regulated at 20 to 30 psi. I would lower your gas  pressure and reset the gas flow rate, check the flow output delivered from each nozzle set at 35 cuft /hr, and then recalibrate


txtReplyBody:
Can you put a pressure gage of the delivery pipe and set it at 20 to 25 psi


txtReplyBody:
Perhaps you should not be trying to match the base metal properties which were developed through heat treat why not use an a 70 or 80 thousand tensile filler metal


txtReplyBody:
ED,

I'm using the following Flowmeters...both calibrated to 50psi:
REXARC   http://www.rexarc.com/industrial/productdetails.cfm?ProductID=112
ESAB L32   http://www.esabna.com/ESAB/showdetl.cfm?st=0&st2=0&st3=0&CATID=10&Product_ID=662&DID=8&CFID=25907&CFTOKEN=99711708 
Do most plants run regulators at each machine?
Like I said before(I think) we have one reg set at 50 psi leaving our mixer feeding the entire plant.  I do have gages close to the flowmeters that do indeed read 50psi.  Should I just buy a million regulators and adjust them down to a very low pressure?


txtReplyBody:
Since you are using ASTM A488, the weld bends only have to bend as far as the base metal can bend before opening up an 1/8" long discontinuity.  If you try to bend a 3/8" thick bend bar around a 1 1/2" mandrel with 4340, it will break with or without a weld in it.  The other option is to use ASME Section IX (which ASTM A488 says is automatically acceptable) and reduce the thickness of the bends below 3/8" thick or increase the mandrel diameter.


txtReplyBody:
stt is pulsed parameters imposed on  short circuit wire feed rates


txtReplyBody:
Josh I would switch the pulse off, use an 035 E70S-3 wire with argon 10 co2, and set short circuit for the parts less than <0.080 and spray transfer on thicker parts

txtReplySubject:
RE: Fanuc robots and Miller Axcess Pulsed power source


txtReplyBody:
contact the lincoln electric web site, stick welding is one of the few things they are good at

txtReplySubject:
RE: weld consumable for API - 5L -60X pipe welding


txtReplyBody:
this information is typically available at the Weld Design Fabrication  magazine Cleveland OH 216  696 700

txtReplySubject:
RE: welding help for university project needed!


txtReplyBody:
YOU ASK ABOUT REDUCING HARDNESS YET YOU DO DONT MENTION THE WELD PROCESS, CONSUMABLE SIZES WELD CURRENT OR AMPS,

txtReplySubject:
RE: Welds hardness of tube-to-tubesheet joints 1.25Cr-0.5Mo material


txtReplyBody:
I have an application that requires robotic MIG welding 2.0 mm stainless steel to 1.0 mm galvanized low carbon steel. Is this feasible? If it is, what wire and gas would be recommended? Thanks. The 1 mm requires you use short circuit, use an 035 wire argon 2 0xy gas mix and start out at 120 - 150 amps 16 volts, 25 ipm


txtReplyBody:
requires short circuit, 035 wire 130 - 1140 amps 16 volts, argon oxy gas try to weld vert down 20 to 30 ipm


txtReplyBody:
sorry, 309 or 310 - 035 wire with short circuit,  130 - 140 amps 16 volts, argon oxy gas try to weld vert down 20 to 30 ipm. I would grind the galvanized edge first.


txtReplyBody:
Ensure that your operators are aware that travel speed needs to be consistent.  Tell them to try a larger cutting-tip size, and adjust the flame so that it emits a 'whistle' sound.  This sound indicates an oxidizing flame that, along with increased preheat from the larger cutting tip, should help finish the cuts.


txtReplyBody:
I'm right there with you.  I am going to attempt to contact the Editor.  thanks for the information.
PWC


txtReplyBody:
Thanks for the contact info.  Rest assured she will be getting a call and some emails.  I am a little surprised to learn that the editor is a woman, I would have expected that this particular decision would have been made by a man.  Women in higher positions generally have more common sense and are less easily influenced by sales tactics than men because they have gotten where they are through good decisions rather than who they golf with.

txtReplySubject:
RE: Weld Design & Fabrication Executive Editor


txtReplyBody:
with an 046 wire and argon, try both AC / DC Pulse at around 200 ipm around 20 volts, when you do this take an amp reading and let me know


txtReplyBody:
I am currently running 40ipm at 90amps in AC-pulse mode.  Will I have enough power with my 200amp power supply to run at 200ipm?


txtReplyBody:
With 90 AC amps have you tried short circuit using an 035 wire?


txtReplyBody:
are you talking about tips for resistance welding? if so use "resistance welding tips" as your key words search. i believe a company in canada has some special alloy tips


txtReplyBody:
if you want a full penetration weld the spec should call for it. If you need a partial penetration weld that requires a specific WELD  strength the weld spec should call out the minimal throat depth. If the weld is there for seal purposes, then test the weld to see if it passes a leak test


txtReplyBody:
if its a pressure gage set 15 to 20 psi , if a flow meter set 25 to 35 CFH


txtReplyBody:
Alex why are you confused? My web section on mig gases spells out and simplifies the MIG gas requirements. Forget what the salesman has stated. My books cover the MIG process, in reality you have half a process. Your power source has limited weld current out put so the bottom line you are welding with short circuit transfer.



-----Original Message-----
From: LXVS@YAHOO.COM [mailto:LXVS@YAHOO.COM] 
Sent: Tuesday, December 21, 2004 10:45 PM
To: ecraig@weldreality.com
Subject: CONTACT FORM FROM WELDREALITY.COM

CONTACT FORM FROM WELDREALITY.COM
---------------------------------------------
FULL NAME------------------:  ALEX STCHEKINE
EMAIL----------------------:  LXVS@YAHOO.COM
PHONE----------------------:  (248)705-3208
FAX------------------------:  N/A
CONTACT ASAP---------------:  Yes


COMMENTS OR QUESTIONS------:


txtReplyBody:
Want to be even more confused? Read the December 2004 issue of Weld Journal that "emphasizes shielding gas".  You will read that the new construction of the Bay Bridge is only feasible because of the "New Tri-Mix" that made it possible.  ........I'm speechless.........


txtReplyBody:
Brad the answer is on this site, go to spray 045 determine the transition start current and thats the end of the short circuit current, ed


txtReplyBody:
When it comes to the subject of welding nobody provides more bovine fecal matter than the gas companies. Its nice to know the welding buisness BS will continue in 2005.


txtReplyBody:
While I was looking elsewhere, a salesman convinced a non-welder manager that he needed multiprocess inverters for a production line that produces a product with GMAW and only has a GMAW weld procedure. The line untill now was equiped with 450 amp cv power supplies. So much for the new year.


txtReplyBody:
And the same to you and yours.
Many Years.

Andrew


txtReplyBody:
Same to you Ed.  Thanks for all your help in '04
PWC


txtReplyBody:
i believe MIG Vac are out of buisness, the vacuum MIG guns do not seem to be that popular in the US,other vacuum systems are in place and most of them are turned of. They were very good on E70T-1 flux cored wires  Ed

txtReplySubject:
RE: Are  mig vac MIG guns still out there?


txtReplyBody:
just click on the topic and the post reply is on the bottom


txtReplyBody:
Your thin to thick application requires pulsed however you are also finding the weld reality on some, not all pulsed equipment. Arc instability leads to welding differences, its a pity you did not check out the OTC pulsed equipment.

txtReplySubject:
RE: Lincoln Power Wave and Arc Stability?


txtReplyBody:
Chris any traditional Lincoln. Miller ESAB CV power souce either single or three phase will surpass your needs. Try and get one that provides at least 250 amps at 60 % duty cycle. A unit with a built in wire feeder is logical. 
Forget that nonesense on the flux cored and penetration unless you intend to do your welds vertical up. Use an 035 MIG wire and argon 15 - 20 co2. I hope after you spend the $1500 to $2300 you will invets in your self and spend a few bucks on one of my books which will optimize your welds.

txtReplySubject:
RE: selecting that first MIG power source


txtReplyBody:
Bernard & Tweco still make vacuum mig guns. Use is pretty minimal due to the weight of the guns.


txtReplyBody:
Chris,
I run a Mig welding class in a very small space at our local community college.  The big three make perfectly fine 250a equipment, but I must say, the Miller w/Fan-on-Demand has reduced noise levels significantly over the ESAB.  If yours is a small shop and noise is an issue consider the fan noise.  Also, on Ed's point... buy the books first.
PWC


txtReplyBody:
With straight CO2 if you are outside the optimum short circuit parameter range you will always produce globular transfer unless you have wasted money and purchased an electronic Japanese power source designed to be used with staright CO2. Go to the MIG gas section of this site for more data. Regards Ed


txtReplyBody:
I have owned and used several Migs and finally settled on the Millermatic 210.  The tapped transformer is bang on with recommended settings and most people, beginner and seasoned welder alike, find it an ewasy machine to use.  Welds up to 3/8" single pass are no hill for this climber.  If you prefer red over blue the Lincoln 215 is another good choice.


txtReplyBody:
Ed,

You said its a pity he didn't check out the OTC pulsed power source.  What makes is better and why?


txtReplyBody:
sorry the person and process are now retired


txtReplyBody:
Eric In contrast to the information you will find in many weld text books or from your weld supplier, spray will occur with 25% CO2 when the amps are over 270, however you will have to set higher than normal weld voltages, typically 30 and 36 volts. Unfortunately few welders like welding with weld voltages in this range. With the 045 steel wire it makes more sense to use < 20 CO2 as the voltage range then is typically 25 to 30 volts. With an 035 1 mm wire the 25 CO2 does not go into controlled spray, small weld drops will be repelled from the wire tip in the typical spray parameter range. Extensive data on this subject in gas section of my site. ed


txtReplyBody:
Its the only pulsed power source I have seen that actually provides ¨stable, consistent¨ parameters in both short length and long length pulsed welds, as long as its used in its optimum ´pulsed parameter range. 

Keep in mind due to the complex electronic requirements of maintaining pulsed peak and back ground current the best pulsed MIG equipment will always be much less stable than a low cost CV power source.

txtReplySubject:
RE: Lincoln Power Wave and Pulsed Arc Stability?


txtReplyBody:
if you are not concerned about the corrosion the argon CO2 is fine and the info from the salesrep should be stored just under the bulls rear end, the one on my site, regards Ed


txtReplyBody:
That tip you describe is one I designed when I worked with ABB. I patented the ceramic/ Cu MIG contact tip. This patent which is now owned by ABB  can be found with a traditional patent search. Coors ceramic in CO made the contact tips which enababled up to a 1.5 inch. wire stick out. We used the tips for robot weld, single torch high speed MIG applications typically 4.8 mm fillet welds at 80 - 90 ipm. When I left ABB they did nothing with the tips.


txtReplyBody:
I forgot to mentiona I usually use .030 wire.  Geat web page by the way.  A great wealth of information!


txtReplyBody:
Our company manufactures a VP (variable polarity) weld power supply and various heads specifically for orbital pipe/tube welding.
  The process is a Tig process and provides full penetration (x-ray quality) welds as proven on numerous aerospace projects.
  If I can help, please contact Dave Liolli @ Liburdi Dimetrics (704) 892-8872

txtReplySubject:
RE: Full penetration pipe weld in Aluminum


txtReplyBody:
The 210 power source will get you into spray at 190 200 amps with 035 wires, less current for the 030 wire. Use argon 2 or 5 oxy as you can use this for spray welds on both the steels and stainless parts


txtReplyBody:
Yes, I have had good luck with the .030" wire so far.  I was trying to avoid having to get multiple bottles of gas.  With the 2-5 oxy is the short circuit mode out of the question?  I was thinking I could run into burn through on 0.120" DOM tubing that I weld with spray.  What do you think?


txtReplyBody:
not if you mechanically rotate the tube and use the higher weld sppeed, the argon oxy is recommended so you can spray steel and stainless without carbide precipitation issues, argon oxy is usuallly fine on SC applications < 1.6 mm


txtReplyBody:
short ciccuit ok < 1.6 mm, on you 0.120 parts if you mechanicaly rotate or use higher than normal manual weld speed low end spray not a problem

txtReplySubject:
RE: AR -8% C02 Mix,                             Final Answer


txtReplyBody:
look to the specific weld data used reference the weld current and gage relationship, for example, Is it ok for welding 1 to 1.5 mm mm dissimiler gage applications but not OK for > 2 mm as the additional weld penetration fom the higher weld current will cause to much weld dilution leading to cracking. Also are there alum type restictions. Reference using this process on carbon steels remember spatter free sheet metal welds can be made on all steel gage applications 1 to 3 mm with minimimal issues from a $1500 power source. Let me know about the demo and promises I have an interest. Regards Ed


txtReplyBody:
Just to clarify what the intentions of the presentation are: not just the welding of steel and aluminum, but the bonding of ferrous material and non-ferrous material together.  I have heard that this is possible with an CuAl wire, which is basically a braze, but have you ever heard of an actual weld (taking both materials to solution) of steel and aluminum together?  I´m aware of the fact that I´m so wet behind the ears I´m lucky I haven´t drowned, but I wouldn´t think this is possible.  Can a grain structure be formed with a combination of both steel and aluminum?  I still have to determine if they should be substituting their ability to "weld" with "braze".


txtReplyBody:
Aluminum bronze has lower melting temp alloys than steel yet provides the strength of steel, with good corrosion resistance (they are exppensive) The Al Bronze wires are good MIG product I have used them on thin < 1.5 mm auto applications with gaps < 3.5 mm and on ferrous to none ferrous parts plus stainless to copper parts. Typically these and sinilar alloys can be welded using either the spray or when lower heat required pulsed MIG process.


txtReplyBody:
May I ask what is CMT? I have read reports  and articles in the Welding Journal about arc welding steel to aluminum using an intermediate that was aluminum / stell that had been joined together by explosive welding.


txtReplyBody:
Cold Metal Transfer I believe its an electric modified form of Short Circuit


txtReplyBody:
The explosive welding that you are talking about is actually called MPW, or magnetic pulse welding.  It uses millions of amps, introduced through an inductor, in a fraction of a second to push the pieces of metal together so fast that it breaks the molecular bonds in each respecitive piece, and then the bonds reform with the other pieces electrons.  I work right beside guys that do this on a daily basis.  The CMT is just a MIG welding process.  I'm just trying to figure out if when they say "welding", if they actually mean "brazing".  The MPW is most definitely a "weld"


txtReplyBody:
For what it is worth, many years ago, I found that I could join coldip galvinize steel to 3003 Al with GMAW using ER4043 and Ar with a short circuit transfer. I was able to to achieve a joint that failed in the aluminum. I am in no way implying that this was a welded joint or of any significance. I found welding to be a fascinating trade thirty years ago and continue to do so today.


txtReplyBody:
well Steve i wish that you could first of all sue Panasonic the power source manufacturer, but all thats likely to give you more head aches. Thhis was a simple MIG spray application 30 years ago and buying that pulsed equipment has made a simple application complex. Switch of the pulsed mode set that 045 wire at 270 to 280 amps, 350 - 380 ipm with 25 to 27 volts, set 30 ipm for the weld travel and see if that power source can at least deliver a stable spray weld. Good luck Ed

txtReplySubject:
RE: Inconsistent Panasonic welds on torque converters


txtReplyBody:
Geez Ed...you can't even buy this good of publicity.  Are you ever going to send a thank you letter to all of the pulse power supply manufacturers for your excellent job security?


txtReplyBody:
there is a good reason this site is called weldreality.com


txtReplyBody:
yes theses are the alum wires. Try Ampco OR WELDMOLD for alum bronze, i am doing well breathing in weld fumes around Atlanta, regards ed


txtReplyBody:
A loaded question. If welding in Florida where the humidity is high the wires could be affected in a few minutes or hours. If you used the same product in weld shop in Chicago where the air is much drier in the winter the product may not be affected by moisture for months. Then there is the wire manufacturing quality concerns. I have used Lincon gas shielded FCAW wires that filled the weld with porosity as soon as the wire was taken out from the box, in contrast i have used reels of Alloy Rod wires and not been concerned about weld porosity. So the bottom line with these wire is 
[a] concern about enviroment variables, 
[b] concern aout storage variables, 
[c] concern about the care and quality that goes into the wire manufacturing 
[d] concern about the wire seam seal design.


txtReplyBody:
Blue first question what is it you weld on a typical day?


txtReplyBody:
i work in a small mom and pop fabrication shop so some days dont do any ,some days like the past week building an 16' x 30' alum. barge we had 5 guys in it for two days straight welding...the shop doesnt have any type of filter system..just open the big bay doors..but still gets alittle much to take...


txtReplyBody:
i should have added that a big majority of are work is aluminum but do steels and stainless..been building 2 to 3 20 to 30 foot boats a year were i do most of the welding on these projects


txtReplyBody:
I would consider first portable fans, ed


txtReplyBody:
If you are using spray transfer the mix you are using is OK however the weld will be more controlable with 10 co2 as less spray volts required. If you mostly SC welds stay with the 20 co2. By the way I write the info on this web site hoping that someone will read it. This gas data is in the gas section


txtReplyBody:
Good Question: The gas mixes creates ionization (electrons collide with gas molecules causing more electrons and protons) When the current settings are high increased gas flow creates increased ionization. Of course you must not set the flow rates at a velocity where they create turbulence for the weld. Helium being a smaller molecule than argon allows more flow rates. The bottom line if you need more penetration first try increasing current and if the current is maxed out increase the gas flow. Regards Ed.


txtReplyBody:
It used to be Linde, however  since inverters and pulsed they variable slope equipment is no longer made. Some power sources will have variable inductance none today have variable slope it was too complex for welders to work out the settings. If you see old SVI equipment come up for sale its great stuff. The pre 1999 Miller Delta Weld 452 was in my mind the best MIG power source ever built, regards ed

txtReplySubject:
RE: SVI. MIG Equipment and best power source


txtReplyBody:
If you are tig welding make sure the gas you use as a purge gas is inert as the reactive part of a MIG gas mix will contaminate the tungsten. You can use that worthless MIG Tri mix for the MIG gas purge gas or send it to Miller so they can use it. Regards Ed


txtReplyBody:
The bottom line is No. Two completely seperate weld processes only related by the equipment used.


txtReplyBody:
For what it is worth? I spent several years qualifying weld procedures and welders to Section IX. GMAW and FCAW are different processes and require seperate qualifications. However, a welder qualified with FCAW or GMAW (except for GMAW-S) is qualified for the other.


txtReplyBody:
With an automated weld its possible. Using a square wave power source in which the polarity is set to focus on the and more than 300 amps I believe a full penetration weld is possible,the issue is control the burn through and the weld surface, sounds like an interesting problem, Any reason MIG is not used?


txtReplyBody:
NICE REPLY MIKE IT SHOWS THEIR IS HOPE FOR THE WELD INDUSTRY


txtReplyBody:
he is someone who should be working in a donut shop


txtReplyBody:
simply because we are once again attempting to eliminate an edge prep process .... I agree however , that the mig process would be the way to go and also my first choice . Thanks again for the timely reply and input concerning this challenge .

E.R. Cauffman


txtReplyBody:
Thanks for the info ... greatly appreciated and very informative .


txtReplyBody:
Not so fast Ed.  There are changes that occur when adjusting argon content.  For instance, increased argon content, without adjustment in parameters, will change bead contour and depth of penetration.


txtReplyBody:
Ed.  I would like to see laboratory test results, if you should have any, that relate a proportionate increase in shielding gas flow rates to increases in penetration.  I also enjoyed your theory on the creation of "new" protons and electrons.  Have you ever heard of physical law?  Ed, if you are going to be so critical of other welding professionals, you should first do your homework and quit spreading further inaccuracies.

To the gentlemen with the aluminum issue.  A power source with an AC frequency control can help to increase penetration with the same overall heat input.  The increase in frequency will give a narrower arc, thus increasing your overall current density.  This should provide for a deeper penetrating weld without going to a helium shielding gas.


txtReplyBody:
Concerning ASME Section IX FCAW/GMAW, transfer mode is an essential variable for welder performance qualification.  See QW-355 and QW-409.2.


txtReplyBody:
Well Bill, 
I'm sure that Ed and I would both agree with your statement.  However, the fecal matter that I was being subjected to is a slightly different scenario.  The salesman was telling me that if I have an ER 70-S6 with 80-20, and I change to an ER 70-S6 with 90-10, I will have an increase in the amount of silicon islands on the finished weld bead.  I have a hard time swallowing the fact that the gas mixture affects the chemical composition of the wire.  It is my understanding that the amount of silicon islands is directly related to that amount of silicon in the wire, not the amount of Argon in the mixture.  How can an increase in Argon result in an increase in silicon islands?  What he tried to make me buy into is the fact that the 90-10 is a lesser energy mix (I agree), and this would increase the amount of silicon islands because less would be burned off due to the lesser energy (not too sure).


txtReplyBody:
My new Miller 350 has variable inductance.


txtReplyBody:
why would you buy a costly pulsed power source then want to get inferior results from a gas that will create weld transfer and turbulence issues on parts over 0.080? ,


txtReplyBody:
Ed, I checked over the steel AISI section, and to be honest I'm a little confused. I do not know much if anything about metals in this sort, I am making a project and I was just wondering which Plate would hold strongest, A36 or 1018 on a CR-1045 cyclinder. I my self am not doing the welding, but am purchasing the products so as my inquiry about the plates, was just curious.


txtReplyBody:
contact ESAB 800 933 7070 and ask for Alloy Rods Dual Shield wire info for your steel


txtReplyBody:
use a traditional E7018 ELECTRODE OR A E70S-3 MIG WIRE. ED


txtReplyBody:
EXCESS POROSITY, LEADING TO LEAKS

POOR FUSION LEADING TO FAILURE,

OR A WELD THAT MAY LAST FOR ANOTHER DECADE, THE BOTTOM LINE IS YOU ASK A QUESTION THAT NO CAN ANSWER ONLY YOU. YOU KNOW HOW TO WELD THIS STUFF BUT IN THE CONDITION THE PART IS IN YOU ARE NOT SURE OF THE RESULTS AND NO ONE ELSE SHOULD BE CONFIDENT.

txtReplySubject:
RE: Welding crack in hydraulic reservoir


txtReplyBody:
Thanks for the reply Ed,but how flammable is hydraulic oil? Does it leave a varnish like gas that can explode?


txtReplyBody:
I am sorry I just dont know the answer, just be careful. Good Luck Ed


txtReplyBody:
Probably has a pretty high Flash Point, but you can get a MSDS fom the manufacturer.


txtReplyBody:
it should not be necessaryif if the welds are prequalified, the correct size welds are used and the part dimensions are within the tolerances in the prequalification. If any of these factors have changed the best way to test the welds is cut them to check the fusion Ed


txtReplyBody:
Does this unit have an output contactor switch? that is in the on position, I've seen this problem when people go back and forth from arc gouging to mig welding and don't turn the output switch off, with this switch on the wire is always "HOT"


txtReplyBody:
Larry in the thickness range you are pulsed welding, this the way to go, however in this thickness range there are no benefits from the costly STT process which simply provides low pulsed parameters, in contrast try a 350 pulsed power source from OTC it will easily out perform the STT and should be at least 50% less cost. If OTC not available let me know the pulse equipment you can purchase. Regards Ed


txtReplyBody:
NDT is used primarily for detecting discontinuities....not penetration and fusion.  Penetration and fusion generally need addressed with a cross section and etch; destructive methods.


txtReplyBody:
With short circuit transfer if you used straight argon (requires low weld voltages)  on parts over 2.5 mm you would have no penetration and the arc would wonder. With the addition of CO2 you get both the benefits of an oxidized surface which enables superior transfer of electrons and the benefit of ionization, see gas section) If you used straight co2 for short circuit you would have to use 2 - 3 volts higher than any argon CO2 mixes. Perhaps the welders are a little confused and mixing up argon 10 co2 when used for globular or spray transfer, at that time the higher  parameter, open arc transfer is off course hotter than short circuit. Again with globular and spray as you increase the co2 content the arc energy is increased. I wish more welders would read first and then have an opinion, regards ed

txtReplySubject:
RE: effect of argon % with arg / co2 mixes


txtReplyBody:
Luke i try to leave some data for my books.
Short circuit over 150 amps flush with nozzle
Short circuit under 130 amps stick tip 3 mm outside nozzle.
All pulsed, glob and spary recess tip inside nozzle 3 mm. Regards Ed


txtReplyBody:
John. As you are using short circuit for the silicon bronze 045 wire its a pity you did not purchase the much lower cost Lincoln CV 400, you would not be having power source problems. Also for those of you new to this site, try the search engine in this section to see if other people are having similar problems use the search words (Power Wave).
  I am amazed that Lincoln or Fanuc did not help you as this appears to be a power source issue, I guess your 36 month warranty is just up. 
 Yes  burn backs can occur frequently if wire restriction issues occur, as you changed the guns and tips and checked feedability, that should rule that out. Go to part two for possible solutions.

txtReplySubject:
RE: 2005 Llncoln Power Wave and erratic wire burn backs


txtReplyBody:
[] Are you using an external volt sensing VS lead? if so  check continuity. 
 
 []If VS lead OK on the power source causing the issues, disenable VS. I have found that artificial inteligence can be unstable when new and the instability can increase with the  aging electronics resulting in erratic power source performance. (an indication that the power source technolgy is beyond the power source mfg) I believe to disenable VS a jumper lead has to be moved in the power source.
[] Disenabling the VS did not work, then disenable arc start and wire burn back functions as these functions have been known to produce erratic results. To displace this data use seperate weld schedules at the arc starts / ends
 
 []If using a laptop weld program,  switch the power source to either the 045 standard short circuit mode for steel / stainless. Its a pity your 36 month warranty is just up, whats that song  "when will they ever learn" 


Thanks to Greg Smith for his contribution,

txtReplySubject:
(2) Llncoln Power Wave and erratic wire burn backs


txtReplyBody:
for more data on this subject visit MIG equipment "part two" go to MIG equipment scroll till the end of section, click on section two scroll down till you find email from Dave marked April 2005, (sorry it was Dave from GM not John)


txtReplyBody:
extensive data in the MIG gas section on CO2 costs and comparison. Question is your company using a Japanese power source that has a special CO2 program


txtReplyBody:
in germany.

   only kidding here is the add I dont know if the phone is current this add is from 1987. this add on the web will get you where you need to go

   DEUTSCHE INSTITUT FUR NORMUNG E.V (DIN)
   D-1000 Berlin 30
   Federal Republic of Germany
   Tel 030 26 01 329
   Telex 184 273 din d


txtReplyBody:
Some, not all are using the Lincoln STT welder.  One big problem is nothing is standard.  We have Lincoln, Miller, and Motoweld in our plant.


txtReplyBody:
Typically when you use straight CO2 your weld cost per part will increase 20 to 50% with the use of CO2, this is caused by restricted wire feed rates and weld rework / spatter clean up


txtReplyBody:
I am assuming that these welders are PW455 machines and not PW450's.  If in fact they are PW455's check the following things:
1)  If burnback is enabled on the Fanuc, ensure nobody changed the burnback settings.  You will find this under Data>F1 Type>Weld Process.  There are 8 different burnback settings in this menu so be sure you go to the one that matches your selected process.  The settings should be set to a WFS around your crater fill settings, and ensure your voltage is set low, around 16-18 volts.  If your WFS is set to say 0 and you have a voltage, it may burn back excessively.  
2)  Also check the condition of your brushes on the feeder motor.  I have had one of my machines give us intermittant tip issues etc, and we had a brush in the feeder with a broken spring causing intermittant feed.


txtReplyBody:
After 160 amps its all you will get. In contrast too argon mix globular transfer, the co2 glob transfer is much more erratic, the droplets larger and much hotter. When welding over 22 volts  > 175 amps use the lowest posiible weld  voltage, you can bury part of the globular transfer in the weld reducing the spatter Regards Ed



-----Original Message-----
From: robnsue@telus.net [mailto:robnsue@telus.net] 
Sent: Thursday, April 28, 2005 4:48 PM
To: ecraig@weldreality.com
Subject: CONTACT FORM FROM WELDREALITY.COM

CONTACT FORM FROM WELDREALITY.COM
---------------------------------------------
FULL NAME------------------:  Rob
EMAIL----------------------:  robnsue@telus.net
PHONE----------------------:
FAX------------------------:
CONTACT ASAP---------------:


COMMENTS OR QUESTIONS------:


txtReplyBody:
Greg I guess you did not see the part about the wire burning back at all three phases of the weld start, middle and end. Go to the MIG equipment section and check out a more likely cause, ed


txtReplyBody:
Matt i use power sources that have not broken down in the last 20 years so i cannot get exited about a German power source that manages to do what its supposed to do.


txtReplyBody:
Volts will always be on there, with the amp setting and Ed's book you should be able to make the translation. Amps AND feed speed would not make sense.


txtReplyBody:
If you are welding at 260 amps you can use an 045 wire. O40 is an excellent wire for welding gage to 5 mm.
 035 should be used if current required for application is < 230 amps
  040 should be used when 260 - 280 amps is to ho for the parts. For a 3/16 fillet 040 is the wire of choice. Lots of data on my site and in my books.


txtReplyBody:
The 035 metal cored will go into spray at 175 amps if you use an argon oxy mix or argon 5 - 10 CO2. Your gun should be ok, ed

txtReplySubject:
RE: .035 ESAB Coreweld 70 for 175A Power Source?


txtReplyBody:
Strange question. SAW penetration is all about current density which is influenced by the power source size you will be using. A small weld wire with medium current 400 - 600 amps or a large wire with a large amount of current 600 - 2000 amps.So check with your supplier at the available weld wire sizes and ask the current range for those wires and then select the wire size that enables the highest weld current from your power source, this will enable you to attain the greatest SAW weld fusion potential


txtReplyBody:
The answer is no. 

                The required weld voltage is a good indicator of the consistency of gas composition you recieve. However to check the gas mixes in your plant you can . 

     [1] Have your gas supplier bring in his costly gas analyser, they usually will do this for free. And as an industry that causes so much confusion and BS they lilkely have an obligation to perform this task.

     [2] GET A GAS MIX THAT YOU KNOW IS OK AND CHECK TO SEE IF YOU REQUIRE THE SAME VOLTAGE FOR A GIVEN WIRE FEED RATE WITH BOTH the MIXES USED. 
   
   [3]TO ENSURE GAS MIXING, ORDER YOUR CYLINDERS WITH DIP TUBES AS THIS PROVIDES SUPERIOR MIXING OF THE TWO GASES, 
ED


txtReplyBody:
We had the same problem with these powerwave 455's where I work. I finally convinced the boss to let us run them in the constant voltage setting and all the problems went away. I'm not sure powerwave is the way to go. Much more expensive than a CV400 and when welds are compared theres not any difference.


txtReplyBody:
dave do you read the equiopment section of this site, if you did you would not be so "unsure" regards ed


txtReplyBody:
Mohammed:
Let me respond to this before Ed blows a gasket - it is not possible to achieve spray transfer with 100% CO2 shielding gas.  You need to have an Argon rich environment (80% or more) in order for the metal to transfer across a stable open arc (due to Argon being a Noble and non-reactive gas).  There are instances where you can use a 75Argon 25CO2 and achieve spray transfer, but this requires high amperage and high voltage with at least a 1.2mm solid wire (don't know about FCAW).  Please check into the Gas Section or FCAW section or Spray section...or better yet: spend the lousy 80 bucks and get the Weld Process Control Book.  If people keep asking questions like this Ed is likely to have an aneurism, and those who deal in reality can't afford that.  I hope this clears everything up for you.


txtReplyBody:
Actually, I made a mistake...you will need the MIG and FCAW book for this, not the Weld Process Control (although I highly recommend it).  Their both about the price of a celebration dinner with some beer or wine or Pepsi for when you get a little weld reality in your life.  I've already enjoyed that dinner, as well as many others who visit this site and drop a little moolah. Good Luck!


txtReplyBody:
Ryan was going to be a politician. No spray with flux cored, its a stream and droplets. The wires that use argon mixes are typically all position wires and the droplets and stream are more controlled.


txtReplyBody:
Hamilton the X65 should tell you something. The welds can be done with SMAW- TIG - MIG - FCAW - METAL CORED - PULSED MIG - STT - RMD - CMT - SAW. 
This is simply a vague question. You know the welding will also have to be done to a number of customer and code specifications. The bottom line is vague questions lead to vague answers and this site is not about vague answers.


txtReplyBody:
My problem is the gas was dictated by a Senior Level V.P..


txtReplyBody:
I may be able to help, but need to know manufacturer, no.of switch positions and if possible can you provide a picture?
In my experience(UK),most power sources at 500A would be thyristor controlled and not primary switched types

txtReplySubject:
RE: transmig 500. course amperage switch selector


txtReplyBody:
Try contacting these people.
  

Murex Welding Products Ltd
Hanover House, Queensgate, Britannia Road, 
Waltham Cross, Herts, EN8 7TF, England.
Telephone (01992) 710000 Fax (01992) 719191


txtReplyBody:
Go to Spot Welding Consultants web site click on "Finger Detect".


txtReplyBody:
We are a large manufacturer and have been providing PAPRs to our welders for years. We have tested several PAPRs and the Adflo is by far the best. Yes, a bit spendy, but the advantages over the old Hornell unit and any 3M, Arc One, etc. is worth it.


txtReplyBody:
Rick,
This pre-qualified joint requires back (post-finish weld) or backing weld (pre-finish weld) and backgouging.  How would you get behind there (other side of joint) and do that?  If you can't get back there to do the work, you can't use the per-qual joint.  Give me more info... I'm sure I can answer your questions.
PWC


txtReplyBody:
Paul,
I guess I am pushing the limit on what is referred to as backing or back weld. On a typical corner or t-joint we weld the inside of the flange to plate up to the web. We then back gouge the outside of the joint full thickness into the back weld and web and fill the joint from the outside. I am turning to CJP because of the fillet requirements caused by skewed joints with up to 1/8" root opening. In most cases we are spending more time placing fillets vs CJP. We have not used access holes for joints of this type (calling them AWS prequalified) for years and have not been called on it. (we are AISC certified) I have just been asking the questions to make the decision to leave alone or qualify the joint. Thanks, Rick


txtReplyBody:
When in doubt, run the PQR.  Damn 'eh!
Good Luck.
PWC


txtReplyBody:
I would like to get to the bottom of this question and it's funny how many different opinions I get (talking on many forums) from so many professional folks. It is too bad the code is not more clear on many of its subjects. I don't claim to be an expert but I have a pretty good grasp on things and I hate to say it, but,  AWS should be more like CWB. At least when there is a question you can call and get a positive yes or no over the phone.


txtReplyBody:
mike first it pisses me off when people send a quaestion , i reply by email and your email comes back thanks to the security system you have set up on your web site which want accet emails from people not recognized. Your weld issue was likely generated by the fact you did not purge which left a highly oxidized root weld which offered minimal corrosion resistance


txtReplyBody:
did you check the 4340 data on the web site under"steel info"


txtReplyBody:
what  do you think this site is "ask jeeves", while on the web look up these words, thyis site is for welding questions that hopefully go beyond the words we use in welldin

txtReplySubject:
RE: Information about ferritic steel. Get a Life


txtReplyBody:
Paul my management and engineers book and mig / fcaw book are a must read. also go to the real world applications at this site and read how Union pipe SMAW welders in two days were switched over to fcaw and the tremendous savings that resulted


txtReplyBody:
all this info and much more is covered in my robot process control self teaching book.
 $100.000.00 for robot cell
 $8000.00 for pulsed power source/
 $500.00 dollars for 500 lb of wire.
 $79.75 to buy a book that makes it all work,

txtReplySubject:
RE: gas wire selection for robot mig application


txtReplyBody:
it would be nice to know the wire type and gas mix you are using


txtReplyBody:
EASYARC 706 .035'' from Lincoln Electric
Argon / CO2
25% Argon


txtReplyBody:
use the lower silicon mg lincoln 70s-3 and change the gasmix to a less reactive argon 10 to 15 co2. All this data is on my site, i have taken the time to write it please take the time to read it, regards ed


txtReplyBody:
there is a resistance weld association RWA whic over the years has been as much use as the AWS. As the resistance equipment will often have unique features, I think that it's best to deal with the resistance equipment manufacturers for info


txtReplyBody:
in the old days I would think this was some time of capacitor problem (stores energy)with this new equipment god knows perhaps some of the Lincoln people who secretly visit this site could enlighten you how their company can screw up the last good MIG weld power source they ever made,

txtReplySubject:
Anyone help with this Lincoln CV400 problem


txtReplyBody:
I'm not really a Lincoln Dude secretly spying, but I do know CV-400's.
Have you isolated the problem to the power supply?  What type of feeder are you running? Could there be a funky start data programed in the feeder?  Give me a call, maybe I can help. Having the small sparks when you touch the work is really a non-issue.  I see this all the time on Miller and ESAB products.
Paul W Cameron
507-269-7142


txtReplyBody:
weld monitors are simply not necessary, weld expertise with weld process controls are necessary.


txtReplyBody:
What about a three shift tier 1 operation where the weld engineer cannot be 100% sure of what the off shifts are doing?  I need a monitor to prove to my customers that the robot welding was done at the required parameters; btw, not pulse.


txtReplyBody:
What wire feeder are you using and how old is it? I've seen this problem on wire feeders without run-in speed used with the CV-400.


txtReplyBody:
You can't use 100% CO2 with pulse welding since pulse is a type of spray transfer.


txtReplyBody:
Is this a Hobart Wire a self shielded flux cored wire. If so no respectable weld shop would use it. Wire feed (current) is the primary parameter responsible for internal weld penetration with all wires, voltage typically will change the weld surface profile.


txtReplyBody:
if the lower tensile wires have more ductility than they will have the best crack resistance. If you are trying to provide higher tensiles provide weld wires with greater tensile strenfth, dont mix up ductility with strength han will be the most crack

txtReplySubject:
RE: ASTM A 519 Gr.1524 / AISI 1527 Grade D RC 23- 30


txtReplyBody:
Andrew you have answered most of the questions, simply take the wire start out with spray curent and set the weld volts too high resulting in a  whoosh or quite spray sound. Then  turn the voltage down till the crackle sound commences and you have the optimum spray crackle sound. When your welders have read a book on mig then you should be concerned about their opinion


txtReplyBody:
If its a lincoln self shield wire i would not use it for a pig pen never mind a penstock


txtReplyBody:
Brad,
If your robot operators have access to changing the weld parameters than you have completely lost control of your process.  No "after-the-fact" monitor will help you.  
If you want to help your customers insure robot operators can not change weld parameters.
PWC


txtReplyBody:
answer is in the steels section, regards ed


txtReplyBody:
It's not the operators.  I have a section head for each shift (3) and we can't guarantee that they all reset the robots the same.  Also, when they are not present, their assistants will 'touch-up' the programs.  We need to verify everything is as we want it.


txtReplyBody:
KEVIN I AM BEGINNING TO WONDER DOES ANYONE READ ANYMORE. THE INFORMATION YOU REQUIRE IS IN THE STEEL SECTION UNDER AISI STEELS


txtReplyBody:
First there is no such thing as a "constant current or constant voltage power source. With TIG and SMAW we use a power source that with a voltage change that derives from an arc length change the current change will be minimal, this results from a steep slope output. With MIG we call it a CV power source however the voltage is forever changing. With MIG for a given volt change we need a larger current change to impact on the constant fed wire and maintain the arc length. To get the large current change (1 volt 25 amps is typical)we have a latter slope. Slope is determined from where you tap into the transformer, ed


txtReplyBody:
Dear ED We are not fussy about innershield. please advice any other Dual Shield wire.


txtReplyBody:
Sounds like I better take a little of my own advice and buy the MIG and FCAW book as well!


txtReplyBody:
Thanks Ed, Thanks Ryan,
Yes you are absolutely right. I have to procure the all necessary stuff from Ed's books. However the process of procurement will take some time. Would you please let me know if any extra shipping charges would apply for Gulf Region. The company I work for is in Kingdom of Bahrain.


txtReplyBody:
There is a bit of clarification still need on mode of transfer in FCAW. As far as I knew, it's GMAW where you speak of Transfer Mode. However ASME IX requires mode of transfer to be specified for both GMAW and FCAW as variable for FCAW are not listed separately. I understand that it's impractical to have Short Circuit mode in FCAW and as you have educated me that it's not even spray so what should specify in the WPS as per ASME IX? Hope you are not annoyed of my silly questions. Please guide me on the subject.


txtReplyBody:
we ship by post office so the charges will be as low as we can go


txtReplyBody:
Hi Ed,
It seems your replies # 7 & 8 are the same. Kindly guide me on my request # 6.
Regards


txtReplyBody:
Ed you sure like a challenge.
 First a few yeasr ago I remember working with an appplication similar in which very high current AC tig was used with 1/8 tungsten, argon helium at 450 amps. I would try this first and check the weld pen depth from one and two sided weld passes.Single pass Plasma keyhole is typically done in the 300 - 400 amp range  with argo - helium  up to 3/8 without issues. You may want to check out variable polarity. the timimg of the dcep / dcen can be critical with alum, quite a bit of data in volume 2 weld handbook eigth edition or give me a call


txtReplyBody:
Does seem as though my superiors don't want to see me getting bored does'nt it !!
Wanted to again say Thanks for the info and timely responce. As always , greatly appreciated.
The reason for my asking the question was because these welds must be full penetration welds completed from one side only ... no double welding will be permitted. Was curious to know if the PAW Keyhole process would or could possibly be a viable solution. Based on your responce and combined with my own conclusions ... I would have to say Yes. Will keep you posted as to the results of this latest undertaking. 
Thanks Again Ed.

Edward R Cauffman
Welding Engineer 
SynAlloy Corp.


txtReplyBody:
It sounds like oxide slag formation thats occuring in a bead too thin. Improve gas flow at weld strats / ends and increase convexity of the welds


txtReplyBody:
Could it be silicates from an electrode like ER70S-6 or -S2 being used on clean metal?


txtReplyBody:
you never mentioned was it a crater at weld completion? You could stop a lot of the speculation if you simply sent me a photo


txtReplyBody:
Good question. A question I cover extensivly in my books and on this web site under short circuit and pulsed. Ask yourself what are the key issues when welding <2 mm steels.
[a] Reducing weld burnthroughth potential,(especially with gaps.
[b] Minimizing distortion,
[c] A tendancy for applying ovrsized welds.
Now ask yourself what process uses low volts, low current, and the arc goes on and "off" many times per second. For steel welds < 2 mm yes you can use pulse on many applications that today use short circuit, however it's very unlikely you will findany measurable weld  benefits. and you certainly wont justify the higher price of the pulsed equipment


txtReplyBody:
all the materials cover the weldability, the specification you weld to tells you the preheat requirements

txtReplySubject:
RE: Material weldability and preheat requirement


txtReplyBody:
I am sending you the pictures in PPT form.

Regards

Fraser


txtReplyBody:
Here's another giggle for ya'.   I was hired because helping companies understand and meet the requirements of the code/standard is what I do.  I hold in my (formerly nicotine stained) hands the single PQR, generated in 1976, that this ISO certified company hung its hat on...   "Pass 1 - 40-220 amps, 15-25 volts, 5-200 IPM Travel Speed  Pass 2-7 - 100-350 amps, 18-30 volts, 12-200 IPM Travel Speed


txtReplyBody:
Thanks paul appreciate the thought, however Design & Fab needs Lincoln advertising revenue much more than they need me, having less to do for them gives me more time to spend on this site. Regards Ed

txtReplySubject:
RE: Re-Post: Weld Design & Fabrication Executive Editor


txtReplyBody:
I THINK YOU WILL FIND THAT MORE THAN 50% OF MIG WELD PROCEDURES IN MANUFACTURING PLANTS ARE MEANINGLESS AND WOULD HAVE MORE VALUE AS TOILET PAPER


txtReplyBody:
Before welding on a vehical, disconnect the battery as ground is part of vehical, I do not know if other electrical components are at risk Ed

txtReplySubject:
RE: welding on car with battery attached?


txtReplyBody:
I started reading WD&F in the early seventies.  I considered it a good resource. Columns such as Mr.Crag's made it acceptable long after it became more ads than articles. Now I find it little morre than an a published infomercial. I fear the same thing is happening with the Welding Journal.
I have no problems with the ads. It is the ads disguised as articles.


txtReplyBody:
i dont suppose you would like to take the time and effort and describe the specific statement. ed


txtReplyBody:
I apologize. I did not realize that only part of the message was sent. I will re-send when I get back home.


txtReplyBody:
Butch this is all covered in the gas section of the web site. 
[1] Argon does not provide sufficent energy for the arc, oxy / co2 provide more heat just like an on oxy - fuel torch. The oxidixing effect super heat enables more electrons to flow.
[2] The black surface with stainless gage applications results with the hot weld reating with the oxygen in the atmosphere. 
[3] for stainless use either argon 2 oxy or argon 2 co2 as you are welding thin gage both will oxidize, on thicker applications > 3/16 the 2 co2 will provide cleaner spray welds. 

THE VIDEO IS IN cd - dvd - video, regards ed 





---------- Original Message ----------------------------------


txtReplyBody:
FOUND AN ANSWER TO MY OWN QUESTION AND NOW HAVE A SOURCE FOR THIS ROD.  MY CUSTOMER SAYS IT WILL BOIL ASPHALT OUT OF CRACKS AND HOLD UP WELL


txtReplyBody:
will forgive the time you spent in sales, it's obvious someone else made you do it. I checked this one out with Alloy Rods and their recommdation for the T1 steel IS A Dual Shield 11 -100. (11=Tw0 roman numerals) size(1/16) all position argon 25 CO2, good weldability with charpies at 28 ft/lb at -60


txtReplyBody:
"As spray transfer weld fusion is at best marginal in most MIG welds, the Mig gas influence on weld penetration has to be the number one consideration foe every welding shop that welds carbon steels thicker than 1/8(3mm). I understand the importance of the gas composition, however I am surprised that " spray transfer weld fusion is at best marginal". I appreciate any enlightenment you can offer.


txtReplyBody:
Philip. The way I would approach twin wire is to use AN optimum set of "moderate weld paramaeters" for the weld mode selected. For example if using spray transfer in your thickness range,  for the lead wire i would utilize atound 400 ipm (045 wire)280 amps and a moderate spray setting of 360 ipm or 260 amps for the trail. If welding with pulsed for both wires I would start out with wire feed settings about 10% less than those I just mentioned, again with two wires and optimum control use moderate settings and make sure the lead wire gets the desired fusion

txtReplySubject:
RE: twin wire parameters, spray defines pulsed


txtReplyBody:
Its marginal because the plasma (energized gas) is narrow in contrast to the size of a fillet weld > 3/16, thats why you get more weld pen at the root than you do at the side walls of a 1/4 fillet. ed


txtReplyBody:
It depends on the pulsed equipment manufacturer. With Miller and Lincoln possibly 450 to 500 ipm with superior electronics such as found in OTC equipment you will posibbly attain 600 to 650 ipm


txtReplyBody:
Jason you dont have a failed weld you do have a failed aluminum part. As you know the part you are welding is a "heat treatable alloy" (T6) and it came to you solution heat treated, quenched and aged. This treatment provides a tensile approx. 45 ksi. The code requires for a welded part a minimun of 24 ksi. As your part failed its likely you have upset the part with too much weld heat. With these and similar alloys watch your weld heat input, [a] Used pulsed, [2]Use heat sinks, [3] no pre-heat, [4] interpass max 200F, [5] no weaves use stringer beads, [6] use lowest parameters with volt set to minimum, use max weld speeds and you will be allright next time. Ed

txtReplySubject:
RE: failed groove weld, aluminum alloy 6061-T6. AWSD1.2


txtReplyBody:
need wire type flux cored or mig and typical weld parameters


txtReplyBody:
Brett try and run two ground cables from the STT, use bigger ground cable try 4 o. Place the ground clamps as close to the pipe joint as possible, also try and operate without the sensor lead. Next time you want to put a pulsed weld in a root consisder a decent pulsed power source like Daihen OTC, it will meet all your MIG and flux cored needs on the pipe line. Let me know how things work out anyone else have any ideas?. Ed


txtReplyBody:
Engineers they are not. 

[A] 3/16 FILLET WELDS SHOULD BE USED.
[B] 035 WIRE SHOULD BE USED.
[C] 70S-3 SHOULD BE USED TO REDUCE MICRO CRACKING FROM THE SILICON ZINC REACTIONS.
[D] METAL CORED A WASTE OF MONEY ON THIS PROJECT,
REGARDS ED


txtReplyBody:
If you want full pen forget back up strip leave a 1/8 root gap and use TIG for the full pen root part of the weld


txtReplyBody:
Sharon the only danger from a welding gas is when welding in a confined space and the weld gas displaces the air you should be breathing


txtReplyBody:
There is no rationalization for any of the welding logic that comes from Corporate Chrysler. Their chief welding engineer has for more than a decade been in the wrong profession. The choice of the 75-25 gas restricts the use of spray transfer on any steel robot welded parts over 0.070 and when used over 200 amps will be the cause of spatter. As for the self shielded wire, no one knows why the Chrysler corporate engineer still insists on the world's worst electrode for coated materials. As for the double coating, it makes no sense. What does make sense is to coat the parts after welding as the weld destroys the coating in the weld area. As I said don't look for logic when dealing with Chrysler..

txtReplySubject:
RE: Chrysler wire and gas spec, are they crazy?


txtReplyBody:
Ed is right about it replacing the air in a confined space, but I have run into one other instance where Argon wasn't really a health threat, but an inconvenience.  If you are welding overhead with an Argon rich shielding gas, and your face is fairly close to the weldment, you can breathe a significant amount of Argon in.  Since it is heavier than air, it can sit in the bottom of your lungs and give you a slight headache, and the feeling that you can't catch your breath.  This was a minor inconvenience, but should be noted.


txtReplyBody:
You can rebuild any steel application with mig, the question is what do you want from the weld, ductility or hardness, if its ductility use a regular E70S-X and use pre-heat and interpass temp control. If its hardness you have a wide variety of flux cored weld consumables available, use the elctrode wire mfg heat treat requirements


txtReplyBody:
James, the bottom line is if you have spatter issues with pulsed weld equipment you have not set the correct parameters or you are not using optimum consumables. In the 40 plus years I have MIG welded I have never required anti-spatter equipment or compounds, regards Ed

txtReplySubject:
RE: Spatter Shield and pulsed MIG welds?


txtReplyBody:
With a meter you check the amps / volts / WF rate. If you are logical for the amps/ volts / wire feed rate you apply + /- 5%,

txtReplySubject:
RE: Acceptance criteria for Calibration of welding machine


txtReplyBody:
without question if the person setting the weld knows what they are doing, MIG can produce a weld that will meet any global quality, standard or spec, and for additional benefits MIG will typically provide that weld at 200 to 500% faster weld speeds at MUCH LOWER lower joules.


txtReplyBody:
For the last 10 years or so I’ve been using this technique… I attach a NIST traceable Fluke to the output studs and only measure voltage (CV equipment/OCV). If the machine is analog, we adjust to meet the Fluke. If it’s digital, we require +/- 5% (mfg’s spec.). If we don’t hit the 5% we pull the machine and figure out why (seldom). 
I don’t measure current because too much influences it. If the feeder is digital, I measure WFS using a NIST traceable Stop Watch and Tape Measure (set WFS, run out 6 seconds worth, measure amount of wire, multiply by 10).  Again, +/- 5%.  If the feeder is not digital there is little I can do.  
Write your procedure so it clearly states what you do measure, and then do it.  We repeat this every 6 months during PMs.
PWC


txtReplyBody:
You can use argon 2 oxygen for spray / pulsed and I would use argon with 3 to 5 CO2 With this alloy take note of required heat treat requirements, some general one listed on the site under stainless regards Ed






----- Original Message ----- 
From: <rex.miller@woodgroup.com>
To: <ecraig@weldreality.com>
Sent: Friday, August 05, 2005 6:18 PM
Subject: CONTACT FORM FROM WELDREALITY.COM


> CONTACT FORM FROM WELDREALITY.COM
> ---------------------------------------------
> FULL NAME------------------:  Rex Miller
> EMAIL----------------------:  rex.miller@woodgroup.com
> PHONE----------------------:  405-214-1447
> FAX------------------------:  405-275-5813
> CONTACT ASAP---------------:
> 
>


txtReplyBody:
Matt As the robot arc on time is no where near a 100% try this 16 robots x 20 cuft/ hr then look at the difference between cyl + rent, Liquid Argon + C02 cyl and Mini bulk liquid argon and CO2. Then is only one prime company that makes mixers and you know who they are. A good mix for your mixer argon with 12 CO2.


txtReplyBody:
Get you self a cylinder of argon with 15 to 20 CO2 and use the Lincoln L50 045 WIRE, Dont forget to spend a few bucks on one of my process control books so you are not playing around with your new purchase, good luck ed


txtReplyBody:
Thanks for the advice, and definitely plan on ordering some books in the near future. thanks again ~Jackson


txtReplyBody:
I beleieve the flux cored section answers this the all position gas shielded fcaw are a poor choice for flat and horizontal welds on plate > 6mm

txtReplySubject:
RE: Preferred Brand Gas Shielded E-70T1 Flux Cored Wire


txtReplyBody:
Suspect you check yor peak and back ground currents.I am using this system with success. Using a complete circular clamp aft side of joint for sensors.
Standard earths for fcaw on the weld.Also use an independent gen set and switch board for STT units you wont get any electrical noise to disrupt STT performance.


txtReplyBody:
First I would fire the supervisor. Second I would get all the pipe he has been responsible for and gouge out his welds as most will have extensive lack of weld fusion on the root and bevel surfaces. Then I would get an 040 or 035 wire and using  argon 8 to 12 CO2 I would set the spray welds and do the job right.


txtReplyBody:
i would use ABB robots and standard CV Equipment ask for "bulls eye" autoamtic TCP controls, a torch cleaning station  and if possible use Tregaskis or Binzel guns, dont forgey my training book and video on robot weld process controls


txtReplyBody:
For what it is worth I agree with Mr. Craig but I thinlk you owe it to yourself to check out American Weldquip and Pac-Mig for weld guns. I am an end user not a sales rep. But either of these companies will make custom torches at near standard at prices to stock off the shelf items made by Binzell or Tregaskiss. I have used American Weldquip extensively and they are much more robust than the other two. I have seen the Pac-Mig gun and cable (uses compressed air instead of water) and the guns and cables are not de-regulated for AR/Co2 mixes as are most guns). I have not use the Pas-Mig gun yet. It is on my to do list with the next application I try either 
for robotic or machine welding. Perhaps Mr.craig has some other experirences with these companies.


txtReplyBody:
I am sure there are many guns out there that are robust, i mentioned two that I know are reliable and the consumables are well made and readily attainable. Last week while doing process control training for a company in Texas, I requested 0.035 tips from Bernard. I could not get the MIG wire to run through the new tips. The wire was measured it was 0.036.


txtReplyBody:
i would never use the bare wire. as the coating is not really relevant why do you want it?


txtReplyBody:
When you come to this part of the site read the information just above the question box. You need to tell me the power source type, the weld transfer mode, the wire feed, amps volts and travel speed, steel type and part thickness, without that data it sounds like you have a pulsed power source thats inconsistent, thats rare.


txtReplyBody:
From what I've seen, the copper imparts a black ugly coating to the weld. I'm interested in a weld appearence similar to that of a tig weld, i.e. shiny weld with a minimum of discoloration due to heat. If I can get that with correct settings, gas choice, and copper coated wire, that would be fine.

Thanks,

Pete


txtReplyBody:
Sorry forgetting providing the welder information.
Part thickness is 3mm. We use Lincoln powerwave 455, 0.045" wire, welding currents are set around 230-250 amps, welding voltage using trim 80-100%, weld travel 60-90 cm/min. Transfer mode is pulsed spray transfer. 7 welding power supplies are for 7 robots; each robot make multiple welds; 7 robots make welding at the same time. When the problem happens, all welds are thin and narrow no matter which robot or power supply.


txtReplyBody:
Problems welds from a Lincoln Power Wave, now thats a surprise. I could tell you here what the problem is however as I have already wrote dozens of pages as to what this problem is, please do me a favour and read both the pulsed MIG and MIG equipment section of this site, your problem is well covered, after you have read that data then call me at 770 330 9933 for an easy fix. Regards Ed


txtReplyBody:
try google search "SAE to ASTM" also contact both of these organizations, I am on road for two weeks, have a good book at home if you dont find data call me two weeks 828 658 3574, ed


txtReplyBody:
Thanks Ed,

I'll follow up on your suggestion.

Pete


txtReplyBody:
Kelly you know this is a ridiculus argument, of course and metal cored or solid wires will have dramatic weld fume reduction in contrast to flux cored. Your welders don't fear extra fumes from the metal cored they fear a weld process change which they have no expertise in. Welcome to weld reality. Ed

txtReplySubject:
RE: weld smoke metal cored versus flux cored?


txtReplyBody:
The copper coating content is so miniscule it simply cannot influence the steel weld surface. Its the silicon and manganese that provides those slag islands. Compare the chemisty of different wire manufactures E70S-3 wires. Typically avoid NS and Hobart wires. Make sure the parts are clean, consider additional gas shielding or larger nozzles and you will get the cleanest weld you will attain.


txtReplyBody:
Thanks. The problem was resolved. The incoming power to the whole weld cell causes the problem.


txtReplyBody:
Jud all this info is in my MIG and flux cored book (eds train materials) and I hate repeating what I have taken the time, energy and money to put in to a book. Regards Ed


txtReplyBody:
If you are using pulsed current over 220 amps or attaining large droplets < 220 amps you may see increased tip wear especially if the pulsed power source is not consistent. In contrast to spray transfer, the action of creating a pulsed weld drop can us more of the wire extension from the tip to work. Inconsistent pulsed equipment is responsible for most pulsed tip issues. Extensive info on this in the pulsed MIG section of this site, ed

txtReplySubject:
RE: Contact tips wear for pulsed and regular CV


txtReplyBody:
Thanks Ed. That helps me understand what's going on.

Pete


txtReplyBody:
Ed thanks for the info.

I have already placed my orders and looking forward to some light reading

Adam


txtReplyBody:
Forget the blue color, look for any evidence of burn through or cut the weld and make sure with a gage part you are not past 70% penetration..Ed


txtReplyBody:
First question is why does your company want to use the world's worst consumables. As this web site deals only with optimum weld methods, you will be better served getting this data for this rubbish from the people who make the consumables, sorry Ed


txtReplyBody:
Typically any decent power source will compensate for incoming power fluctuations what was your issue and how low was the input power that it caused a problem for this power source, ed


txtReplyBody:
If weld current should be 230 amps, the acutal current could be 180 amps. The problem happened occasionally, so it is hard to tell what is wrong.


txtReplyBody:
Dont believe its input power, have you checked WF or current calibration?


txtReplyBody:
Mike first. To provide an inteligant answer to a pipe weld question the person asking the question should provide all the relevant weld and edge prep data.    
  Your ROOT porosity is classic center line 
porosity and typically results in a pipe root due to the weld bead solidifying too fast from a bead that is too narrow. Send all the appropriate weld data and we will get to the solution, ed


txtReplyBody:
if you note, on this power source you have a switch that can be set at three settings,
[1] UPPER Stick setting, 
[2] Middle SAW CV Setting,
[3] Lower. CV Self shield (fcaw) setting.
Using either the stick setting or CV fcaw setting you will have  steeper slope (restricted current)Use the SAW CV setting and you should be drawing 240 - 250 amps, which is correct for that wire feed rate.


txtReplyBody:
the osscilliscope pulsed readings shown in the MIG equipment section indicate the same current instability


txtReplyBody:
Best ASM / SAE book 

      "ASM Metals Reference Book" Second or later edition from American Society for Metals


txtReplyBody:
You need good pulsed equipment argon and an 045 276 wire. To optimize the weld you will use transition wire feed settings found between the short circuit and spray fir this wire and voltage in the 21 to 26 range. You will need the ability to change the pulsed parameters to optimize the normal sluggish  weld fluidity to provide a controlled weld that provides consistent weld fusion.


txtReplyBody:
Thanks, Ed. If we use only a single MIG power source, I may think that MIG power source inability. Seven identical MIG power sources happened with the same problems at the same time, it is logical to consider the dirty power input for MIG power sources. Is it right?


txtReplyBody:
Flux cored due to slag entrapment potential in the fast freeze narrow root is illogical. MIG 
short circuit or low parameter pulse is tHe process to use, regards Ed


txtReplyBody:
charles, what you do is check the chemistry of this steel with the available chemistry of the tool steels at this site then use the weld and heat treat recommendations for the steel that has the closest chem, regards Ed


txtReplyBody:
After reading your reply I am confused, to say the least.  I *thought* in your other replies, etc. that you liked FCAW very much.  I thought "self-shielded" was FCAW designed for gasless operation.

Please straighten me out!  Thanks.


txtReplyBody:
why would you use an 052 wire with spray for out of position welds, provide more data this will be interesting


txtReplyBody:
We use .052 because its cheaper than .045. Lincoln DC600 welders with LN7 feeders 23-25 volts, not sure about amps, about 320ipm wire speed. We are welding 7 guage to 1/4", metal thickness ranges up to 3/8". Mostly flat position but occasionally vertical down. Deflection usually occures vertical down with the lighter guage  material, usually when you cant get the gun at the angele youd like to be in, because of a corner. This doesnt happen often but I was wondering why it happens at all.


txtReplyBody:
Dave read the MIG spray transfer section of this site. Your parameters are glob transfer, the wire size is simply too large.


txtReplyBody:
Larry you are in for a number of potential weld issues.

[1] Bevel is too narrow, at minimum go for 50 degrees.

[2]Critical area is the root, open up mimimum opening to 0.150.

[3] Your high deposition can work against you filling up your narrow groove to quickly and not allowing time for the weld fusion. I would have used a smaller MIG wire, 035 set at 500 to 600 ipm.

[4] I would not have used Pulsed i would have used regular spray and as this is a multi-pass weld used argon 10 CO2. Do many cut outs and examine the cross sections before approving the procedure, good luck Ed


txtReplyBody:
I have said all I know on this subject in the safety section of this site.


txtReplyBody:
from a weld and durability perspective both are excellent


txtReplyBody:
Hery. Ther rebar is high carbon steel, and yes it can be welded. Keep in mind the rebar welds will destroy some of the rebar strength. However the welded rebar can be then tied to other unwelded rebar to attain the desired strength in a specific location. Regards Ed.



----- Original Message ----- 
From: <welderbluecorvette@yahoo.com>
To: <ecraig@weldreality.com>
Sent: Tuesday, September 27, 2005 5:43 PM
Subject: CONTACT FORM FROM WELDREALITY.COM


> CONTACT FORM FROM WELDREALITY.COM
> ---------------------------------------------
> FULL NAME------------------:  Henry A.Hankey
> EMAIL----------------------:  welderbluecorvette@yahoo.com
> PHONE----------------------:  410-800-0498
> FAX------------------------:
> CONTACT ASAP---------------:
>
>
> COMMENTS OR QUESTIONS------:


txtReplyBody:
i would write "tack" underneath the arrow in middle and on top of the arrow on right side the length of the tack  - with the pitch (center to center) distance of the tacks. I would also phone AWS in Miami and order the AWS A2.4 Standards for Symbols, ed


txtReplyBody:
You could just purchase a Chrystler Product! ha ha

txtReplySubject:
RE: Ed Craig wants bad weld stories and pictures.


txtReplyBody:
I'm working on that.....hopefully a change is coming.


txtReplyBody:
You should see the power source voltage go up typically 2 to 4 volts is norm the weld should be flatter (wider) and possibly a little cleaner. Regards Ed

txtReplySubject:
RE: argon helium , pulsed MIG and weld volts


txtReplyBody:
this is not a gas problem it is a procedure and technique problem call ed at 777 330 9933

txtReplySubject:
RE: Recommended gas for Robotic MIG weld of HSLA to 1020


txtReplyBody:
The peak and background have a much greater impact on the weld shape and fusion potential than the pulsed width / frequency. A change in weld frequency will have more of an imact on the weld transfer characteristics. Ed


txtReplyBody:
I am almost positive that the Dual Shield means its the origional Alloy Rods Product, call ESAB at Hanover facility and ask for sales mgr or lab tech they will confirm, regards Ed


txtReplyBody:
Saul, this question is well covered in the gas section of this site. The bottom line is CO2 provides gas dissociation properties, oxy does not. The molecular occurence with the dissocation properties (see MIG gas section) provides much more weld energy which simply results in superior weld fusion especially when the gas mixes contain 10 to 20 % CO2.

txtReplySubject:
RE: weld penetration, argon oxy versus argon CO2


txtReplyBody:
Mike For data on this subject visit the end of the robot tips section also found in spray and pullsed  sections.


txtReplyBody:
Ryan. The fact that you are forced to deliver an answer to this question is a sad reflection on the engineers who bought the question to you. With high strength low alloy steel parts over 2 mm, spray transfer has been the process of choice since the steels introduction. If you look at the joules heat inputattained  you will find the robot weld travel rates achieved with the higher weld deposition spray, (higher weld speed, 30 -60 ipm) minimize the affect on the heat affect zone width. In contrast to the way the frames are welded you offer superior weld fusion, lower weld heat input, higher weld quality, greater productivity process changes and your recommmendations are  are being resisted by individuals who are not qualified to make those decisions. By the way a simple load test on the globular welds (which always have lack of fusion and the spray welds would tell your doubting Thomas engineers everything they need to know.


txtReplyBody:
The only reason to pre-heat most grades of stainless is to eliminate moisture. Passing an oxy fuel torch on the part so you have 70 to 100F will ensure moisture is gone, regards Ed.

txtReplySubject:
RE: How to pre heat stainless steel when ambiant temp below 10°C?


txtReplyBody:
its a poor mans, third world way of welding, commom in the seventies when extensive CO2 was in use. With low cost CO2 you go from short circuit to globular transfer. Use lower than normal weld voltage with the globular and you drive the wire into the weld reducing but not eliminating the spatter. If you spend $40 and buy an argon mix the weld spatter should no longer be a problem.


txtReplyBody:
Answer; Give Huys industries a call, (416 747 1611). This Ontario, Canadian company has a line of resistance welding tips which are coated with titanium carbides. Huys claim the coating greatly reduces early tip deformation, cavity formation and electrode sticking. 

The tests carried by this company have indicated that the tip when used in the mid weld current range will produce approximately 2000 welds before the tip needs dressing. On galvanized the same tips are producing 7000 to 8000 welds before the tip required dressing.

txtReplySubject:
RE: resistance weld tips  aluminum / galvanized


txtReplyBody:
send me a picture of the weld at ecraig@weldreality.com, regards Ed


txtReplyBody:
James I think you will be disapointed in the end results. I am not aware of any University in North America, Japan or Europe that at this time provides an effective "weld process control" education. I have worked with at least 7 OSU graduates and most will be the first to tell you that their weld process control education started the day they got their first welding job. The problem is global in scope. Universities have simply failed miserably in understanding the mig weld needs of industry. This is one reason you see the extensive lack of best weld practices and weld chaos in many plants. If you are good with robots read the process control books at this site and practice what you read and you will have so many opportunities it will make your head spin.

txtReplySubject:
RE: CONSIDERING OHIO STATE FOR WELD DEGREE


txtReplyBody:
Ed
I would have to disagree.  Most places would not even consider hiring an engineer without a degree, regardless of whether he is carrying your book or not.  However, the education does not end with the degree.  An engineer who does not continue to learn and to improve him/her self is indeed a worthless engineer.  But, a person who would utilize ALL resources available to help them on the job will have many opportunities, as Ed has stated.  Whether 
Ed likes them or not, the education system is what it is.  You have to play the game to play the game.


txtReplyBody:
[a] Brad please keep in mind that more than 80 percent of robot lines today in North America are not mangaged by engineers, they are managed and kept running by technicians. 
[b] Also keep in mind that technicians are just as open to learning as engineers. 
[c] Engineer or techicians, this really is not my point, my point is simple. Universities dont provide the weld engineer graduates with the tools they need to establish best practices or process controls. Name me one major company in N America that does it right. 
[d] Of course the degree will get you into the door, as an engineer its what you achieve when you are on the job, and I have not seen to much evidence in manufacturing that the four year degrees provide the tools required.


txtReplyBody:
Ed
Other than technical schools or medical schools, NO programs really substitute experience for book learning when it comes to an education.  A four year engineering degree can only introduce a student to the basics of engineering: Physics, chemistry, metallurgy, and materials.  Please forgive me for going to college when I could have taken 30 years of hard knocks as you did.  My message was that the degree only gets you into the door.    EVERYONE, regardless of education or experience needs to continue to learn and to learn from all avenues available.  Ed is a good source, but not the only source.  Same as for schools.  You can also learn from welding salesmen, but be prepared, as Ed has warned, that they will give you their slant in order to move their equipment.  If you do find a honest salesman, make sure you support their business, don't just shop for a $10 saving.


txtReplyBody:
Brad I am not  knocking going to school or the value of a degree, I am knocking the schools for not delivering what you paid for.


txtReplyBody:
I am not an engineer. I totally agree with what Ed and Brad have told you. There are several good schools turning out excellent people engineers and technologist, but who lack understanding of process control. I will say this I have worked with about a dozen O.U. welding engineers and while I have met a few jerks, their overall knowledge has been superb. Quite honestly, a weldin engineering degree from O.U., some hands on experience and studying Ed's books and avie, should allow you to be ready for what ever comes your way and give you the ability to command top dollar.


txtReplyBody:
If you want a "hands-on" engineering degree, look into Pennsylvania College of Technology.  They will teach you why it works, then make you go out and make it work.  The courses are highly technical, and they are lab intensive.  You spend every day in the lab welding, with a few days a week in the theory room learning why what you just did worked.  www.pct.edu.


txtReplyBody:
Hey!! I like this forum!! 

http://www.7icon.com/  - look at my free collection of beuty and fashion
http://www.7icon.com/
http://www.7icon.com/

go to http://www.7icon.com/ 

online fashion magazine for men and women

7icon.com

txtReplySubject:
look at my free collection of beuty and fashion


txtReplyBody:
Matt. For ship yard management to resolve ongoing weld issues, they typically  would have to  make dramatic changes and to make those changes they must first take responsibility for the issues. When management / engineering has a partial understanding of a  process typically they dont want the ownership. In ship yards there is often poor relationships between office and shop floor workers The shop  guys typically dont like change, (after all this is the way we have always done it)Sometimes its hard to know who is more afraid of process change the workers or management. My books, CDS and this web site  are my training school, good question, regards ed. 


---------- Original Message ---------------------------------- 
From: <mattgrubbs@yahoo.com> 
Date:  Fri, 4 Nov 2005 10:49:48 -0500 

>CONTACT FORM FROM WELDREALITY.COM 
>--------------------------------------------- 
>FULL NAME------------------:  Matt Grubbs 
>EMAIL----------------------:  mattgrubbs@yahoo.com

txtReplySubject:
RE: Confused. Its all about management responsibility,


txtReplySubject:
online fashion magazine for men and women


txtReplyBody:
I have developed the world's most comprehensive robot process control trainig  program. At the same time I hve made the subject simple.Its extensive yet simple and it gets the MIG weld quality / productivity message across. Check out my training materials section, Give a worker the right tools and training and the results will be staggering, good luck ed.

txtReplySubject:
RE: I need to train our robot programmers>


txtReplyBody:
Ed, has anybody mentioned the smaller John Deer tractors made in India? The front axel weldments are lousy, under cutting etc. May be structurally ok but look like welded by basket weavers. My farm repair welds look better. You need to get some pic's of that crap.


txtReplyBody:
Long time Ed! What do you think of fronius's Cold Metal Transfer method for use in joining carbon steel to aluminum? is this for real or is this more hype like Lincoln's STT? 

EDS REPLY: Its for real, however I personally would want to hang any engineer by his b___s if he designs a part in which steel is welded to alum. The cold metal tranfer relies on the fact that miniscule weld fusion is attained. In other words you walk a fine line. If you  cross the plus line and have a little too much dilution severe cracks will likely result, if you cross the minus line, no weld penetration. I am interested in this process for welding parts less that 1 mm. The ooptimum package is now aded to my training materials section of the web, if you wish to talk about this call me at 770 330 9933 or 828 658 3574, Regards Ed

txtReplySubject:
RE: CMT via Fronius & optimal training package for community college


txtReplyBody:
While attending the school of hard knocks I was able to make a pretty good living. Nine months in trade school learning the basics, working the “off-shifts” (where far more opportunities present themselves) and a willingness to “drag-up” when the learning opportunities dried up. Also an occasional college class, a course in TQM and constantly applying what I learned to what I was doing. Certification as a CWI. This route has worked out quite well for me. Today I work part-time for an off-road equipment supplier, because I can. The rest of my time is spent pursuing my other business interests. If you enjoy robots and want to become good at weld process control, make sure that, whatever route you take, you’re getting plenty of hands on experience. Make sure you look for every opportunity to learn (that often could mean working 2nd of 3rd shift).  If you ain’t learning… move on. If you find you don’t enjoy it, get out. Livin’ the Dream, PWC


txtReplyBody:
yes it will work, from a weldability point of view my pref is Sanvik stainless for MIG and Alloy Rods stainless for FCAW, ed


txtReplyBody:
Hey!! I like this forum!! 

http://www.7icon.com/  - look at my free collection of beuty and fashion
http://www.7icon.com/
http://www.7icon.com/

go to http://www.7icon.com/ 

online fashion magazine for men and women

7icon.com



txtReplySubject:
look at my free collection of beuty and fashion !


txtReplyBody:
With many questions so much data is missing and this is one of them is thisa robot or automtated welder? Perhaps you could provide the data as requested in this section. regards Ed


txtReplyBody:
charles this subject has extensive data in the pulsed weld section of this site, regards Ed


txtReplyBody:
Scott for site / shop work a multipurpose power source so you can do TIG / STICK / MIG /FCAW Welding.  TIG is the process of choice for many food applications.Each process takes a LITTLE  practice to put a weld down, however if you really want to do outsatnding welds read as much as you can on the processes and keep practising the skills. For shop / site you may want to consider a small Invertor with multiprocess capability. For site work only you can purchase a small 250 amp multiprocess generator. Equuipment available at Lincoln / Miller / ESAB. With MIG and TIG weld the stainless the way you weld steel except consider the weld electrodes and gas mixes. Get the MIG and flux cored book in my book section and you are on the way with these two process, 
Good Luck Ed


----- Original Message ----- 
From: <sjazell@netins.net>
To: <ecraig@weldreality.com>
Sent: Saturday, November 12, 2005 9:23 PM
Subject: CONTACT FORM FROM WELDREALITY.COM

txtReplySubject:
RE: What equipment for site stainless welds


txtReplyBody:
never heard of "Railway Type" Its likely A36 steel therefore any 7018 or 70s-3 wire ok, if not A36 you need to be more specific

txtReplySubject:
RE: What kind of electrode to be weld between Railway type36 with Carbon steel plate?


txtReplyBody:
Shawn sometimes I get a really good question and this is one of them.

     For robot applications < 0.070 i would use short circuit before pulsed. The SC mode is arc on / arc off, therefore less potential for weld burn through especially if weld gaps are involved.  For applications >0.070 to 0.150 pulsed fits the bill and will typically allow the use of higher wire feed rates than short circuit. Welding >0.150, take your choice of spray or pulsed. If weld penetration is the issue, go with spray. If spray with an 035 wire is too hot go with pulsed using either 035 or 045 wires and argon 5 to 10 CO2.

txtReplySubject:
RE: when to use short circuit or pulsed or spray?


txtReplyBody:
Hey!! I like this forum!! 

http://www.7icon.com/  - look at my free collection of beuty and fashion
http://www.7icon.com/
http://www.7icon.com/

go to http://www.7icon.com/ 

online fashion magazine for men and women

7icon.com





for photo update..
 
jewelry stores,kays jewelry,jewelry television,body jewelry,tiffany jewelry,jewelry boxes,jewelry exchange,gordon's jewelry,wholesale jewelry,tiffany's jewelry,ilver jewelry,zales jewelry,men's jewelry,jared jewelry,fashion bug,fashion games for girls online,victoria's secret fashion show,express fashion,fashion designers,fashion institute of technology,men's fashion,fall 2005 fashion,fashion design,80's fashion,fashion tv,fashion magazine,fashion models
 





txtReplyBody:
It's little more than a gimick. Show me an application I cannot weld sucessfully with a round wire and I will quit this buisness,


txtReplyBody:
Hey!! I like this forum!! 

http://www.7icon.com/index-clothes.htm  - look at my free collection of beuty and fashion
http://www.7icon.com/index-clothes.htm
http://www.7icon.com/index-clothes.htm

go to http://www.7icon.com/index-clothes.htm 

online fashion magazine for men and women

7icon.com





for photo update..
 
jewelry stores,kays jewelry,jewelry television,body jewelry,tiffany jewelry,jewelry boxes,jewelry exchange,gordon's jewelry,wholesale jewelry,tiffany's jewelry,ilver jewelry,zales jewelry,men's jewelry,jared jewelry,fashion bug,fashion games for girls online,victoria's secret fashion show,express fashion,fashion designers,fashion institute of technology,men's fashion,fall 2005 fashion,fashion design,80's fashion,fashion tv,fashion magazine,fashion models
 





txtReplyBody:
The MIG / flux cored book has alL the flux cored data you need FOR THIS PROCEDURE,


txtReplyBody:
Hey!! I like this forum!! 

look at my free collection of beuty and fashion

http://www.7icon.com/internet gambling.htm
http://www.7icon.com/internet gambling.htm
http://www.7icon.com/internet gambling.htm


go to http://www.7icon.com/internet gambling.htm

online fashion magazine for men and women

7icon.com





for photo update..
 
jewelry stores,kays jewelry,jewelry television,body jewelry,tiffany jewelry,jewelry boxes,jewelry exchange,gordon's jewelry,wholesale jewelry,tiffany's jewelry,ilver jewelry,zales jewelry,men's jewelry,jared jewelry,fashion bug,fashion games for girls online,victoria's secret fashion show,express fashion,fashion designers,fashion institute of technology,men's fashion,fall 2005 fashion,fashion design,80's fashion,fashion tv,fashion magazine,fashion models
 





txtReplyBody:
the primary reason for weld interpass temp control with steel applications. With  MULTI LAYER WELDS there is a need to control and minimize the grain growth that will occur in the steel alongside the weld, HAZ area.


txtReplyBody:
Ed,

Does your book specifically discuss ceramic backing? I purchased your book Gas Metal Arc & Flux Cored Welding Parameters, briefly scanned the book and did not find any reference to ceramic backing.


txtReplyBody:
Slope. The measurement of the volt amp curve, the current change per volt change and current out put limit. 

Steep slope SS restricts the amp output during the wire short circuit. Use for Short circuit.035 WIRE < 200 amps < 20 volts. SS reduces spatter and weld drop size.
Flat Slope FS. Spray > 200 amps > 24 volts. 035 WIRE. FS enables more current and a larger current change per - volt change. FS = higher current, faster response to high wire feed rates. FS enables a neally consistent arc length during wire stick out variations during the weld.
AS each QA imited in size go to next reply for how to set the slope

txtReplySubject:
RE: how to set slope on an SVI Linde Power Source


txtReplyBody:
If slope is numbered 1 to 10 and you dont know if the low numbers are steep or flat do the following.
[1] Put the steep slope at # 1.
[2] Set the wire feed at 350 ipm (12 o'colock)
[3] Set at 20 volts,
[4] record the weld amps on meter,
[5] change the slope setting to # 10 and then do the same procedure, the resulting amp change will tell you where the SS or FS is.
[6] If the steep slopeis at #10, for short circuit < 200 amps set start out with the slope set at # 8, and for spray transfer set at # 2 
[7] If the flat slope is the higher numbers for optimum spray start out at # 8 and for short circuit # 2.
[8] Once you set the slope and you could use more / less energy in the weld without a change in wire feed, then adjust the slope up or down one number.
[9] If you have inductance on this power source set it in the middle and leave it alone.

txtReplySubject:
RE: Setting SV slope POWER SOURCE part 2


txtReplyBody:
Why are you concerned about ceramic or any type of backing?


txtReplyBody:
Big Difference. There is a stainless section in the "steels program" of this site that shows the difference, regards ED

txtReplySubject:
RE: what a difference between material A312 TP304 with 304L?


txtReplyBody:
Rather than the 1100 wire, use a 4043 wire  as its much easier to use. As the part is 2 inches thick I would use MIG and use a 60 helium 40 argon mix As for the best weld process of course you can TIG weld with argon but to speed the job up consider MIG spray transfer, with 045 wire. As for the procedure its all about weld penetration. What ever process you use first weld a small section and check the weld fusion profile attained. Regards  ed


txtReplyBody:
Who knows what the Europeans will hatch up. They certainly will not want to use gas mix logic such as A-CO2-25 which would be argon with 25% co2, or A-O-5 = argon with 5% oxy. They certainly will not want to copy the AWS spec, so you can be certain they will make their spec as complex and twisted as the European driven ISO specs. Also keep in mind the welding world can readilly get by on six gas mixes for all steel / stainless / aluminum applications, so it will be interesting to see the gas marketing sales hype they include in their gas spec.


txtReplyBody:
We were looking at trying to weld 1/4 A36 plate together using E71T-1, 0.045 dia. wire without having to backgouge the opposite side. A permanent backing bar would be costly to remove.


txtReplyBody:
http://7icon.com/joke/autorank.html

http://7icon.com/joke/autorank.html

http://7icon.com/joke/autorank.html

Contents in this site - joke of the day,funny joke,the aristocrats joke,blonde star joke,joke frog,joke pictures,thanksgiving joke,killing joke,farsi joke,joke sites,joke websites,iran joke,joke videos,tagalog joke quotes,funniest joke,daily joke,yo mama joke,joke frog.com,sms joke,your mama joke

click 
here to go
 

1.Outside a muffler shop: "No appointment necessary, we hear you coming." 

2.Outside a hotel: "Help! We need inn-experienced people." 

3.On a desk in a reception room: "We shoot every 3rd salesman , and the 2nd one just left." 

4.In a veterinarians waiting room: "Be back in 5 minutes, Sit ! Stay!" 

5.At the electric company: "We would be de-lighted if you send in your bill. However, if you don''t you will be." 

6.On the door of a computer store: "Out for a quick byte." 

7.In a restaurant window: "Don''t stand there and be hungry, come on in and get fed up." 

8.Inside a bowling alley: "Please be quiet, we need to hear a pin drop." 

9.In the front yard of a funeral home: "Drive carefully, we''ll wait." 

10.In a counselors office: "Growing old is mandatory, growing wise is optional. --------------------------------------------------------------------------------  

http://7icon.com/joke/autorank.html

http://7icon.com/joke/autorank.html

click 
here to go


txtReplyBody:
WHAT ABOUT 50-60 DEGREE VEE PREP WITH 1/8 GAP USE SHORT CIRCUIT FOR ROOT AND spray or FCAW FOR FILL


txtReplyBody:
It looks like EN 758 may have the designations.

Brief description found here:  http://www.key-to-steel.com/Articles/Art83.htm


txtReplyBody:
Thanks Brian, that spec has Euro data on electrodes need the equiv on gases call you next week, ed


txtReplyBody:
Our customer specifications will not allow short circuit GMAW.


txtReplyBody:
http://7icon.com/car/autorank.html

http://7icon.com/car/autorank.html

http://7icon.com/car/autorank.html

click 
here to go
 


WASHINGTON (AP) - Ten 2006 passenger cars won praise from the insurance industry Sunday for offering top-of-the-line protection to passengers in front, side and rear crashes.
The Insurance Institute for Highway Safety announced a new designation, the Top Safety Pick award, based on the performance of vehicles in their crash tests.
Winners of the institute's gold award included the Ford Five Hundred and Mercury Montego with optional side air bags; the Saab 9-3; the Subaru Legacy; and the Honda Civic four-door. The Five Hundred and Montego are corporate twins and were considered by the institute to be the same car, for award purposes.
They earned top scores in frontal offset and side impact tests, and a test that reviews seat and head restraints in rear crashes.
The silver award went to the Audi A6, Audi A3 and Audi A4; the Chevrolet Malibu with optional side air bags; and the Volkswagen Jetta and Passat.
....................................................


http://7icon.com/car/autorank.html

http://7icon.com/car/autorank.html

click 
here to go


txtReplyBody:
http://7icon.com/2fashion/autorank.html

http://7icon.com/2fashion/autorank.html

http://7icon.com/2fashion/autorank.html

click 
here to go
 

Jewelry may be one of the buys of the Christmas season, with many discounts being offered, and most jewelry prices don't reflect increased prices for gold.
Jewelry usually sells well before Christmas, said George Whalin, chief executive of San Marcos, Calif.-based Retail Management Consultants.
The holiday season is a very good time to buy jewelry because of the deals. You have to be knowledgeable about what you want, but there are bargains to be had for consumers, Whalin told CNN/Money.
Gold prices have been hovering at about $500 an ounce, while platinum has exceeded $1,000 an ounce, but most of the jewelry being sold was made before the run-up on gold.

click 
here to go


http://7icon.com/2fashion/autorank.html

http://7icon.com/2fashion/autorank.html

http://7icon.com/2fashion/autorank.html


txtReplyBody:
Ron it would have been nice if you had said what pipe bead the cracks are in I will therefore assume its  the root. This type of crack typicallyiss a hot crack and occurs for two reasons,
[1] bead to concave, add land, slow down pass and less weaving helps.
[2] weld electrode needs increased strength.
Again Ron read the information just above this QA, a good weld question provides all the relevant weld data. Have a good Christmas in Saudi, in my mind thats the country  the American troops should have invaded instead of Iraq. Ed


txtReplyBody:
Don there is hope for two reasons 
[1] you have the ability to recognize you are having a problem and therefore you will get the solution. 
[2] you went past the salesman to ask for weld advice. 
For cost and quality effectiveness you should be using either an 045 MIG wire with spray transfer for those flat and horizontal welds if the parts are clean, frre of mill scale and rust. The 045 MIG  wire requires > 260 amps to get into spray. Typically 280 to 350 amps would be typical with a 10 to 15 CO2. If the parts have millscale, for the flat welds use a 1/16 Alloy Rods E70T-1 at  320 TO 380 amps. For vert up a 045 E71T-1 Alloy RODS WIRE 150 TO 250 amps. So as you see these commom COST EFFECTIVE weld wires tell you why a 400 CV MIG power source is choice for most weld shops. Regards Ed. Have you considered reading my MIG and flux cored book all the settings are in there.


txtReplyBody:
WHEN I SEE A QUESTION LIKE THIS I WONDER WHY YOU WOULD NOT ASK THE MANUFACTURER OF THE PARTS


txtReplyBody:
As the web site inform Co2 does spatter free welds with an 035 wire up to 160 amps in the short circuit mode, after 160 A you get globular transfer. With this power source you have a short circuit thin gage MIG welder. Your built in cylinder is not a "high" pressure cylinder that would be required for argon mixes, so less liability for Miller. All the data you need on gases is in MIG gas section.  By the its been my experience with these small power sources that "you never buy a toy when you can buy a tool". If you want a low amp power source buy a stick welder. Happy Xmas ed


txtReplyBody:
Adrian push pull systems for alum is of course  logical, what is even more logical is to have a pulsed alum MIG program in the power source.
The bottom line with push pull and the ALUM pulsed Mode any > 300 amp unit from Miller, Lincoln, OTC or ESAB will work with little difference in the alum weld characteristics, regards Ed


txtReplyBody:
Ed, where is the bad weld section? It's probably right in front of my nose, but I can't find it.


txtReplyBody:
Thanks for your response Mr. Craig. I am trying to set up a demo with OTC to try out there DP400 so that I can compare it to the MillerMatic 350P. The OTC is not a push pull system but they use a 15' mig gun and there welding engineer told me that that setup can weld from 1/16" on up without changing the wire. They are selling it for $7700.00 and the miller setup with push-pull sells for around $4200.00 do you think MM350P will do the same? Is the price differance justified? I need to set up a demo with Miller also so that I can properly compare.

Thank you,
Adrian


txtReplyBody:
First that OTC price sounds a little inflated, but I do like the OTC equipment. Look the bottom line is demo both units on your typical application and then look at the price of the complete package. The pulsed equipment from both these manufactures have made great improvements in the last two years.


txtReplyBody:
Ed,
If it were your choice what mig power supply and mig feeder would you choose as the best all around for aluminum, steel and stainless? I want to explore all my options not just the bells and whisles.
Thanks,
Adrian


txtReplyBody:
With the hard plastic line ensure you  use a "10ft or shorter gun". When welding  keep the gun as straight as possible and make sure inlet / out let guides are as as close as possible to drive rolls. Recess the contact tip insude the nozzle 3 mm and before you strat welding cut the wire stickout back flush with the nozzle, regards ed


txtReplyBody:
I have made it clear that at this time when using pulsed welding my choice for a 350 to 450 amp CV/ Pulsed power source is the OTC equipment, however if you find this equipment too expensive I would look at compatble equipment and price differentials  from either MIller or ESAB. By the way be very aggresive in shopping on the web for welding equipment you will see big price differences than those from your local supplier. ed


txtReplyBody:
David WITH MIG and the correct parameters utilized, undercut is typically weld  voltage set too high, (ARC LENGTH SET TOO HIGH) the resulting arc energy is generated mostly on top of the weld, and this energy creates extra weld fluidity which causes undercut. With TIG again reduce arc length and minimize weave dwell times. Regards ed.


txtReplyBody:
Japanese or American. Would you rather have a toyota or a ford?. With pulsed MIG equipment we are talking about "electronic" equipment, and you know there are no American companies that can compete with Japanese electronic mfgs. If you need pulsed my choice is  OTC, if you don't need the pulsed mode I would recommend you stay with traditional American CV equipment, regards Ed 


---------- Original Message ---------------------------------- 
From: <chskns@wccta.net> 
Date:  Thu, 29 Dec 2005 22:44:02 -0500 

>CONTACT FORM FROM WELDREALITY.COM 
>--------------------------------------------- 
>FULL NAME------------------:  Dean Hoskins 
>EMAIL----------------------:  chskns@wccta.net 
>PHONE----------------------:  515-389-3489 
>FAX------------------------: 
>CONTACT ASAP---------------: 
> 
> 
>COMMENTS OR QUESTIONS------:


txtReplyBody:
Yes you are right short circuit is short circuit, though with straiht CO2 the short circuit weld  energy is typically higher due to higher weld volt requirements. The big weld energy difference is with the CO2 globular mode and argon mix spray mode. 

  For more than three decades argon mixes have been the mixes of choice and the fact that a torch is rated with straight CO2 is another indication of one screwed up industry. Ed


txtReplyBody:
Mike good question.
From my perspective certification is meaninless and has about the same value as toilet paper. You can be certified with any weld process and still do a lousy weld  and on top of that be brain dead. Irrespective of the certification required, on a new job the welder will still likely be given a test to show their manual skills. If I was a young welder, my ambition would be to not become an "old welder". Use your head not your hands. Learn everything you can on MIG weld process controls and use that expertise to become a good robot weld technician, weld supervisor or weld shop manager. Mike why inhale weld smoke when you can enhale fresh air. Regards Ed


txtReplyBody:
http://www.weldreality.com/bad%20weld%20section.htm

Copy and past this into your address bar.

Pretty scary to read!


txtReplyBody:
at top of home page you find link to all weld programs, one program for bad welds industry, the other program bad welds auto / truck industsry.


txtReplyBody:
Ben you have welders afraid of change and apathetic process management, welcome to the welding industry. My advice to you is dont get too settled with that job as they will likely be out of buisness within two years.


