# tblReply

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you would glue it, there are glues out there that are as strong as welds


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Ryan:

[1]SHORT CIRCUIT APPLICATIONS One tip at start of the shift.

[2]SPRAY TRANSFER If the weld cycle times are small and the weld lengths are less than 4 inch, one tip at the start of the shift.

[3] SPRAY TRANSFER If the weld lengths are longer than 4 inches or weld duty cycle high change tip at shift start and after lunch. Remember if the tip bore is not worn it does not have to be discarded.

[4] PULSED SAME AS 3.

Changing the tip twice a shift  gives the operator a chance to examine the gun and make sure the gas bores are not getting blocked by weld spatter.

Remember a spool has a tighter cast and may cause more tip wear than a drum or wheel, regards Ed


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Two horny anime cheerleaders plays with eachother


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As the argon CO2 gases you get are provided at high pressure (2200 psi) both gases  will  be in the gaseous state. If the gases are mixes correctly either through spinning the cyl or adding dip tubes the gases mix completely and will stay in the mix composition  state. Its only when the gases are not mixed correctly that you will draw the CO2 from the lower half of the cyl. A cylinder designed for high pressure argon is typically used for any argon mix. To me its not logical for you to mix your own gas as typically one mix will do the majority of you steel applications, if however you weld alum and steel then it makes sense, ed


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Please send resume to ryan.good@dana.com

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Please send resume to ryan.good@dana.com


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I,m interested in mixing my own gas also can you please give me a list of the equipment that you will be using and how to do it.Thanks Adrian


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stainless pulsed spray or short circuit simply use argon with 5% C02 and forget the salesman


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Jason. As you are using the pulsed mode, use 70 argon with thirty percent helium, a 60/40 hellium mix would also work. This gas mix will enable one to two more weld volts and increase the weld fluidty, which with automated welds should enable a 10 to 20% increase in weld speeds.

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RE: argon mix to increase production for inconel or stain?


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I would like more info on gmaw plug weld you can contact me at (734)728-7311.


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I should also have mentioned that if the pulsed weld wettability or weld fusion needs to be improved, rather than use the 40% helium mix go to the 60% helium mix


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most of the affects will come during the weld, however i would not like to eat my supper in close proximity to any application in which galvanized welding takes place. The bottom line in robot cells is operators are too frequently breathing the fumes that escape from the cells. 
I am sure most mangagers would not want to breath that stuff so why allow the employees the privalege. Sometimes fans that blow the fumes back into the robot cells are highly effective


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The max fillet size should be 5/16 for the following reasons.
[] Concern about attaining consistent side wall fusion.
[] Concern for excess weld heat which occurs when  welds > 5/16 will take the joules heat input over 60,000 kj


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Brian. If you really want the best control you will switch the equipment over to the traditional CV spray transfer mode, as this will provide both consistent and higher weld energy with the 12 to 15 lbs/hr deposition rates you should be attaining on your application. As I HAVE MENTIONED A 1000 TIMES ON MY SITE WHEN LOOKING FOR THE BEST WELD FUSION AND MOST CONSISTENT WELD CONTROL, TURN THE PULSE OFF. Use an 045 70s-3 MIG wire and argon with 12 CO2, and use a wire feed of 380-480 ipm, 26-30 volts and watch the welding magic begin. Or ask Miller / Panasonic about the pulsed welds, then cut their welds to examine the weld fusion and watch the welding circus begin. Regards Ed/


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I would watch the following with the gas shielded flux cored duplex wires. 
    [] Arc length sensitivity, how often you keep changing the weld voltage during the weld.
    [] Wire flare ups (just watch the wire during the welds) caused by innconsistent flux chemistry.
    [] Porosity and worm track potential, can be very high with these welds. 
    [] Slag coverage consistency.
    [] Ability to spray without excess spatter with moderate weld parameters.


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Equivalent electrode is the All state 80LV Red distributed buy ESAB Welding & Cutting Products.
Best Regards 
Bill


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Short tip approx 3 mm recessed in the nozzle should be used for MIG spray, pulsed and flux cored applications.
 Longer tips should be used with lower parameter short circuit applications.  
   As to the difference with the weld wires and tip lengths, unless all the variables were constant (and provided) there is no answer.


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treat it the same as a conventional mig steel weld


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As you weld stainless the following weld considerations infuence the process required.
[]High distortion potential.
[]Cleaning and oxidation concerns.
Its logical to use use TIG or the MIG short circuit process 035 wire < 1/16 gage and the pulsed process for stainless welds from 16 gage to 1/4. For thicker use the gas shielded flux cored process. Therefore consider a good pulsed power source with good CV out put characteristics, Price approx $4000 to $6000.


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The best process with conventional MIG equipment for welding gaps is the short circuit process  and the best wire siz is 035. 
  The optimum SC current is 140 to 180 AMPS with 035 WIRE. 16 - 17 VOLTS
   WE TAKE THESE OPTIMUM PARAMETERS AND EXAMINE THE PENETRATION AND GAP WIDTH POTENTIAL AND THE RESULT IS A 1/8 GAP WITH A LAND OF 1/16 TO 3/32


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go to the alum section for data  on metal, for process used pulsed mig 046 wire and argon for fill and TIG for root.


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you are right...we have been trying ESAB new pulsed system for alum - runs well when running; wire feed problems; Miller runs ok when running - no wire feed problems ez'r to program - customer may not allow GMAW-P will see


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the customer would be foolish not to allow a process that will reduce costs and readily meet any code requirement, ed


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optimum pulsed parameters, 

   []Optimum Pulsed Wire Feed, is typically found at the transition between short circuit and spray for the specific wire diameter, 
   [] Optimum Peak Current, spray transition current for the wire diameter plus 150 to 200 amps. 
   Opt Back Ground 40 to 80 amps set 60A to start 

   Optimum pulsed width 1.8 to 2.0 mhz


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you cannot effect the mechanical properties at <400 F, however if hydrogen was present it may still be dispersing at 400f


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What effect will the dispersing hydrogen have?


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remember when we hace concern for hydrogen cracking a combination of facors  drive the concerns. before I go into the issues it would be more logical foy you to provide me on what you are welding and why anyone would want to quench a hot steel


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We are welding a threaded fitting (.88 sq.)  onto a 3/16 wall tube.  Our productioin supervisor wants to hand this directly from welding to a CNC operator for I.D. machining of a goove.  The purpose is to reduce handling time by eliminating the need to store the weldament on a cart, and then for that cart to be unloaded again.


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should be no problem, however I would tell your supervisor to get a life and smell some roses.


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For all robot MIG data simply purchase the self teaching MIG process control book in the training resource section of this web site, ed


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Go to the flux core pipe section for this subject

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RE: WHATS  DIFFERENT BETWEEN SST AND RMD


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Try 80 amps and an arc length tuning of a negative value...This will define your arc length cone small and narrow. Then set wave pulse at 2.5-3 Hz. Travel at about 20 IPM.


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Fraser glad someone is awake in Scotland. The bottom line. I would consider metal cored wires that could provide special mechanical (tensile, yield, impact, corrosion  properties not attained with solid wires and thats it. Info should be under MIG equipment / consumable evaluation, How will Scotland do in the world cup?


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Hi Ed
    having shown you boys how to play rugby last week  we have decided not to rub salt into your 
wounds by sitting this one out
                       Regards Fraser


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I'd like to hear more.  Can you send information on this?


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Hi Ed,
I've purchased your GMAW/FCAW book and it is a wealth of info. I was just looking through the posts here and noticed on an earlier post that you suggest Alloy rods (which is now ESAB from what I read on that post) and on this post you consider the ESAB coreshield 11 rubbish. Is this because of the manufacturer, or the fact it's self shielded ?

Thanks,
Mark Ovenden


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i think i have written three million words on the subject under "MIG equipment evaluation"

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RE: Lincoln CV400 vs Miller Deltaweld 452, MIG only


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As you provided no data on the consumables utilized, i will have a guess. It sounds like the SAW mechanical properties and MIG wire mechanical properties are incompatable. Evaluate the yield properties of both consumables. Also its possible the weld dilution from the SAW weld into the root provided a root weld with higher strength and "less ductility" than the SAW weld. If this was the case for the root you may want to use a wire that offers "less strength, or you may need a post heat treat, by the way if you visit my pipi section you will find the correct STT parameters. 


---------- Original Message ----------------------------------


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AS BOTH ARGON AND HELIUM ARE INERT, FROM A WELD CHEMISTRY PRSPECTIVE THESE GASES "CANNOT" REACT WITH THE WELD CHEMISTRY THEREFORE THE ADDITION OF HELIUM TO ARGON CO2 CANNOT HAVE AN IMPACT ON WELD CORROSION PROPERTIES. THE HELIUM ADDITION CAN AFFECT POROSITY AND INCREASE PENETRATION WHICH WILL INCREASE WELD DILUTION DECREASING CHEMISTRY, AS ALSO CAN THE ADDITION OF WELD CURRENT. 

To attain  the highest chemistry from a MIG wire for single pass welds do what we do for stainless and inconel welds. Use pulsed MIG and "straight argon"

 GOOD QUESTION, BAD EXPERT, REGARDS ED

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Three part gas mixes and corrosion resistance


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If you are in a country where no argon mixes are availabe and you are using robots and straight CO2, using spatter shield has great value. \

If you have argon mixes (argon <20 CO2), available for your robot welds and weld spatter is an issue its because you need process expertise, read a book. Regards Ed.


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Chris words dont cost you anything, how about a little more desrcription, for example the material type, weld type, size, length the parameters, consumables part condition you get the idea.  If I had to make a bind guess my first instict from your frugal description in contaminates on weld surface, ed


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Ray you likely need a single phase, >200 CV amp unit preferably with built in wire feeder, 035 wire and argon 20 co2 mix. Go on E Bay I am Sure someone will have a second hand unit. Any Miller, Lincoln Hobart, Linde ESAB unit will work well if its in decent condition. fOR THE GAGE WELDS Use 10 TO 12 o'clock wire feed positions with 17 to 20 volts, regards Ed

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RE: BEST MIG WELDER FOR MY APPLICATION 'PLEASE'


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ED In your suggestion to me (Thank you) you said,
" I need a single phase>200 CV Mig Welder.
ED, just what is that ?
Also about the Argon mix such be: 20 co2mix?
Does is that? Do I order that when I go to the welding supply hse. and ask for that mix in the bottle or do I mix that percentage with my gauges?
This is for mig welding car sheet metal.
THANK YOU SO MUCH ED.
GOD BLESS YOU AND YOUR FAMILY.
RAY M.

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ED ~ PLEASE EXPLAIN I'M NEW TO MIG WELDING


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What will you plug thw power source into, your home is single phase at a shop you may have three phase. read the MIG gas section of the site to get the info you you need on the weld gas,regards ed


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if they are not interested you should not be interested. Its not a power source issue that rockwell is very hard, and the center cracking is typically a hot crack situation which in this case caould be the result of a number of variables, Ed


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Thanks for your very quick reply Ed

I agree Ed Case hardened & Nickel plated. Now Ed, will a 312 Stl. st. or weldmold 888 provide the elasticity to overcome the brittleness which I feel is going on here. Presently no pre heat or post heaty going on buy there weld provider for I saw the weld procedure sheet which only spoke of clamping part and what tack they do in what order.


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312 with high ferrite will help resist cracking the HAZ will be a mess irrespective of what you do, Use low heat imput, small CONVEX WELDS welds and interpass max of 300 F to minimize HAZ effect. Why people heat treat small parts  before welding is beyond me.


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The coating makes no difference to the consumables or weld transfer mode selected

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RE: staniless and chrome guards coating?


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Just a thought,it may not be applicable but I have used aluminum and silicon bronze to braze weld (GMAW and SMAW) case hardened and tools steels if the load would allow it.


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there is only one power source out there that gets the job done. The CC/CV multi-process Miller Proline. Use RMD for the vert down root and pulsed MIG using the same steel or metal cored wire for the vert up fill pases. Yes after almost three decades Miller has finally got its pulsed act together and optimized the pulsed process so it can actually weld pipe.


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Frank already working on it visit the MIG equipment section of the site imporatnt new data, ed

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RE: NEW DATA ON PULSED EQUIPMENT / PIPE WELDING


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Over the years I have not been impressed by Bernard quality or durabilty, I also prefer screw in contact tips. I believe much better quality is found with Tweeco - Binzel - Tregaskis products


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I would expect if you want full weld puddle control with that pipe pulsed MIG welds  to achieve 3 to 4 lb.hr versus 8 to 11 lb/hr fof gas shielded flux cored wires. Ed

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RE: Deposition rate pulsed MIG and pipe welds


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DAVE 

   It depends on the code utilized, the thickness, the application, so sometimes you will require post heat and sometimes you wont, 

REGARDS ED


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Steve these type of fundamental process control questions are covered extensively in my MIG self teaching process control book. Tip to work or MIG wire extension, minimum 1/2, max 3/4 opt 5/8


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Just going off memory so this should be verified, but as I recall:
ASME B31.3 - need PWHT for anything thicker than 3/4"  
ASME VIII - PWHT at 1.25", possibly 1.50" if 200 F preheat is applied;
Some pipeline codes - 1.25"
These are construction guideline.  For process concerns, may have to PWHT at lesser thickness; if handling ammonia, or sour gas migh have to PWHT to avoid envirnmental cracking.


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The only benefit of the helium is to provide increased weld fusion. If you are using pulsed MIG, remember that by switching to spray transfer or a larger wire you can increase weld fusion. 
I look to helium typically when the alum is > 3/8. A mix containing 30 to 40% helium provides great cleaning action from the argon molecules and additional weld energy from the helium.


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I would not ban its use, these products are fine for none code products. Lets face it with perfect weld wire and oil or lubricant as found for example on most car parts you will end up with the same weld results, "porosity"


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For ref use the AWS structural code guide lines. With the appropriate AWS weld guidelines a procedure can be a simple document

This MIG weld is made with a wire feed setting of..... Voltage Range.... Amp Range.. Wire Stick out.... Travel Rate... Gun Angles.... Wire Type/Size Gas Mix and flow. Weld Gap Tolerances. Part surface Condition before / after weld. Any NDT requirements. 

 With the weld data in place you then simply reference that these welds will meet the AWS Strucctural Code Requirements bla - bla. If you have an engineer or technician have him sign the paper and if you have a manager thats interested have him sign from a corporate responsibilty perspective. To ensure the weld meets the application weld fusion requirements, you will have done a weld pre-qualification procedure and kept the evidence. The bottom line this weld document has the same value as a document in accordance with the ASME code. You are responsible for welds no code takes responsibiliy.


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Larry instead of the E70T wire consider an 035 
(1 mm) E71T-1 (ALL POSITION) with an 80 - 20/25 CO2 mix. That 175 amps will enable you to do all the steel welds you wish.


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This data is well covered in the MIG gas section of this site. You typically add oxy or CO2 to argon to add to the stability of the electron transfer and add energy to the weld. However if you were stuck in the middle of IRAQ and the only weld gas you had was straight argon, you could likely produce a weld that would not be any worse than those mixed gas MIG welds produced daily in most automotive plants, Ed

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RE: Can I use straight argon for welding steels?


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Jim. The bottom line is you should not need the device you are looking for. If you are getting 30 to 40 cuft/hr of uninterupted gas flow out of the end of the gun nozzle and people leave the regulator flow setting alone, from a weld gas coverage perspective thats that. Your porosity is likely not a result of gas flow, but a result of surface contaminates or a result of excess flow. If the weld is clean on the surface but contains small pore porosity you have a part contamination issue. If the weld is clean and contains large pore porosity you have an excess flow issue. If the weld surface is grey, oxidized and contains porosity you have a gas coverage issue, all this data and more in this site. Ed


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With the traditional spray transfer mode you have to look at weld current compatibility with the application, the weld and the welder. 
  With the 045 wire we have a spray transfer range of 250 to 400 amps delivering 10 to 16 pounds/hr. To attain a higher weld deposition rate than 16 lb/hr with the larger weld wires you have to surpass >400 amps, On most parts when welding with >400 amps, you quickly will find out out why <400 amps is better suited to the application, weld and welder. Ed

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RE: Best MIG wire size for high depositiion rates?


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You are using a 1/8 wire, there will be no high speed welds with CO2 there will be enough weld spatter to fill a politician's mouth.

    Let me know what your weld, applications, quality and speed objectives are and I will then provide optimum data, Ed


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Application: Spiral pipe forming-welding from coil,purpose of this GMAW weld is to hold formed pipe togather till subsequent SAW welding is done. quality reqd: UT & RT clrd. (API spec.),speed can vary from 2m/min to 8m/min.,CO2 insisted for cost reduction.


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WHAT WIRE FEED RATES (ipm) WILL YOU ATTAIN WITH THE WELD WIRE, WHAT PERCENTAGE OF WELDS WILL NOT MEET YOUR QUALITY STANDARD. WHOEVER IS ENCOURAGING THE USE OF CO2 WOULD BE WELL SERVED IF THEY SPENT 30 MINUTES IN THE GAS SECTION OF THIS SITE.


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As you have rightly said, "the best way is to show them". Is 80Ar+20CO2 , stick out=20mm, ipm=205 , V=26 OK at arc travel of 5m/min.?


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as with many questions at this site, you provide too little data for anyone to provide an answer that would make sense

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A complete answer requires a complete question


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Bo. If using the 1/16 1.6 mm wire and welding fillet welds <1/4 you can push or pull, once the fillet weld size is > 5/16 using the pull technique provides better control of the puddle. Wire sizes larger than 1/16 tend to produce a large weld puddle which wants to get ahead the wire therefore the pull method should be used.


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12 gage - 1/8,stainless, weld in the spray transfer range of > 420 to 650 ipm. (210 TO 240 AMPS IS A GOOD. Welds too hot, set wire feed to 500 ipm, weld volts 24 - 25. Move fast, fore hand, weld SIZE < 3/16.  Welds go black due to the oxidation of the part / weld with the atmosphere. Mechanical wire brushing will bring back the shine. Outside corner welds on gage, best weld position, "vert down" Ed


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Current compatability with the part thickness and the weld deposition rate attained is what drives the selection of th ecorrect size weld consumable. For pipes with a wall thickness < 1/2, without question the 045 1.2 mm gas shielded, all position flux cored wire welding in the 140 to 200 amp range 24 - 26 volts provides welders with the greatest control of the weld puddle particually in the overhead position. For pipes with wall thickness > 1/2 and diamewter consider the 052 but keep in mind the 045 is always easier to use.

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RE: How do i choose the best size all pos flux cored wire?


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Brandon, it primarily depends on a the pulsed equipment.=, 

[a] With some pulsed equipment the pulsed data is suited to welding 20 gage, with other equipment the pulsed paramaters or equipment performance may be better suited to 18 or 16 gage.

  By the way a real benefit of pulsed on thin gage is forget 035 wire and use the less costly 045 wire. The 70S-3 is the wire of choice for thin gage.

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RE: What gage thickness can you weld with pulsed?


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John try the all position 045 E71T-1 ESAB "Ultra SHIELD OR ANY KOBELCO PRODUCT, ED


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Wow it took out all my enters. I also left out per AMS 2.4


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CHARLES THIS IS A DOUBLE FILLET WELD SYMBOL. 
[] AT THE TILE END TO THE LEFT OF TRIANGLES PUT THE FILET WELD SIZE BOTH SIDES OF THE ARROW LINE. [] TO THE RIGHT OF THE TRIANGLE PUT THE WELD LENGTH ON BOTH SIDES OF THE ARROW. 
[] TO THE RIGHT OF THE LENGTHS ON THE TOP SIDE PUT THE PITCH. IF NECESSARY  ADD A NOTE IN THE TAIL END AND BINGO CLEAR AS MUD


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you are putting less weld in than that attained from controlled spray with an 045 wire. Ed

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RE: Shielding gas for high speed GMAW. Final


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Check flow of C02, 30 To 35 psi should hold.And check the voltage ,drop the voltage 1 to 3 or 4 volts.


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Justo sorry we dont allow incorrect weld data on this site,we leave that for the AWS site. The worm tracks and porosity are typically a result of a poor manufactured or contaminated (moisture in the flux) weld consumable. Think about your advice, you said lower the weld volts 1 to 4 volts,
[a] If you have set the correct voltage and you lower the volts by 1 volt you have excess spatter.
[b] How do you think lowering weld voltage (lowering weld energy) can decrease defects caused by moisture?

  As we get older the ones who use life experiences think before offering advice, and we make sure that the advice we provide is technically sound. I would recommend you read the flux cored section and  it would also help if you read one of my books on the subject


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Push or pull give the finish weld the convexity and  the penetration at the root of the weld.


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Of course using TIG is a logical practical way to repair any weld defect.


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It would be beneficial to have the procedure used, single pass weld size applied and application thickness and weld joint considerations, like restraint


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If the excess baking did not damage the flux, you should have no problems from the excess bake

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RE: Over baking of low hydrogen electrodes


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Take a highly oxidizing 100% CO2, add a weld wire like a E70S-6 and the combination of high silicon, manganese oxides will result in slag islands on the weld surface. To eliminate use E70S-3 and argon 10 CO2, ED

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RE: brown slag islands from pulsed weld?


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Ed's Answer:

Larry this overpriced power source and costly three part gas mix was not a great choice. For example you could purchase the Miller 350 P with an argon - 5% CO2 mix for stainless. This power source and low cost gas will provide optimum PULSED welds on all your carbon steel / stainless or alum applications from 20 gage to any thickness And this power source costs less than $4000 (dollars). Ed


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If you get involved with this arc data monitoring equipment you might as well shut down the robot line. I will let you figure out why I dont require this equipment, and why it will cause you more probelems than it will resolve. Ed


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Ralph the only thing you did wrong, was to meet and talk to an idiot weld supervisor. We do not utilize the E71T-1 wires for an open root welds. These weld wires provides good weld penetration characterics suited to the PIPE fill passes not the root. You would use ths wire if the root had a back up bar. It's a sad reflection in 2006 with the world shortage on weld personnel that an oil company would hire an idiot like this.


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Steve without doubt the wire in some locations will contain moisture, however as you weld this will be eveident by porosity and worm tracks. The wire will either make sound welds or welds with occasional porosity. You could always grind the porous sections out. Forget the vacuum. If you weld use a long stick out as this pre heats the wire. Use high end weld parameters and straight CO2 will also provide more weld energy. If it was me I would dump this wire, as the world already has too many bad welds, Regards Ed.



---------- Original Message ----------------------------------
From: <ammfg@cox.net>
Date:  Mon, 17 Jul 2006 22:17:09 -0700


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Something is upsetting the weld metal flow to the pipe. At it's a Hobart wire check the cast / helix, especially the helix. Also ensure you use a minimum length wire guide from the feeder to the head. Feel the wire is it runs through the guide and make sure there is minimum motion in the wire guide when welding. Keep an eye on the contact tip bore and replace when bore shows sign of wear. My choice for these wires is an Alloy Rods product for carbon steel welds. Regards Ed

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RE: automatic flux cored pipe line welds.


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Victor: I am sure somewhere on my site that i inform welders that it's useless to purchase these toy MIG power sources < 200 amps, and who the heck is Chicago Electric? You purchased a useless toy that does not like weld current. Forget about spare parts, its wasted money on top of wasted money. Look to Miller, Lincoln, ESAB for real world used or new weld equipment. Sorry for experience, Ed

---------- Original Message ----------------------------------
From: <alejandro>
Date:  Tue, 18 Jul 2006 14:27:55 -0400

>CONTACT FORM FROM WELDREALITY.COM
>---------------------------------------------
>FULL NAME------------------:  victor
>EMAIL----------------------:  alejandro
>PHONE----------------------:  787-415-4255
>FAX------------------------:
>CONTACT ASAP---------------:  Yes
>
>
>COMMENTS OR QUESTIONS------:


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Mechanized welding as with robot welding is all about using logical process control data rather than cutting chunks of contact tips or cleaning nozzles. The logical solution is first establish, weld end data that places less weld heat on the end of the wire reducing the glob dimension on the wire tip and then utilize the correct burn back data. This is the data taught in my low cost process control training program. Ed

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RE: contact tip issue mechanized twin arc welding


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I think the only places I've seen Chigaco Electric welders sold was at WalMart and Harbor Freight Tools...and frequently in pawn shops ;)


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go to careerpath.com use welding for key word, also monster.com


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if its sold in walmart it has to be made in China.


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(cont)First, which book would be more appropriate for a small-time welder, such as myself, operating manual MIG welders of <300 amps? None of the applications I have in mind will exceed welding steel and/or aluminum thicknesses >3/8".

Second, your website notes that only credit card orders will be accepted for orders <$500. My question is--would you allow me to send a Money Order to buy the book? If so, who do I make out the MO to? I would like to properly educate myself in the "art" and unlearn alot of the "myths" and "common knowledge" I've picked up from my Dad and fellow welders. Unfortunately, I no longer use credit cards, as I got myself into serious debt with them, and now my credit is too poor to apply for one. And I'm sure there may be others out there in the same boat.


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(cont)I saw on another post that some A-hole from Tyler, TX refused to pay for his books. Well that is an embarrassment to a Texan like myself (San Antone) since I know the value of hard work, and I know what it's like to have someone cheat you out of honest pay for honest work. I did some trailer work a while back for a guy who paid me half up front, waited till I had the trailer finished, and came and took it right out of my front yard in the middle of the night without paying the second half (my mistake was telling him it was ready the night before) Anyway, sorry about writing a novel here, bottom line--can I pay without a CC?


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The way I currently do these kind of welds is to postion the part in the flat position, weld as far around the circle as I can, turn the part, and start the bead over the end of the last one. The main problem I'm having is that the beads tend to clump up where they cross, leaving a large weld profile. Very ugly :( Any suggestions?


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there is only one way rote the part in a positioner and weld vert down, ed


txtReplyBody:
Thanks for comments. Order the MIG and flux cored book, (red cover) $79 plus $10 shipping. Do it through mail, send to E Craig, 2 Fern Cove Rd, Asheville, NC 28804 make money order payable to E Craig,  regards Ed


txtReplyBody:
Thanks Ed. You should be getting an order from me within the next week.


txtReplyBody:
The PowerWave is certainly not necessary and on this application the pulsed mode will provide more long term equipment issues than day to day weld resolutions. I would suggest you stay with a low cost, more durable CV MIG power source and with the spray mode use  an 035 or 040 wire with argon 10 CO2.  You will attain optimum weld quality and productivity. Good luck with your career Sara and remember in the weld industry dont believe what's told you till you try it for yourself. Ed

txtReplySubject:
RE: spray or pulsed on these robot parts?


txtReplyBody:
A $1000 is a little shy for new equipment. When buying new, look at the Millermatic 251 which sells around $2300. Then go to Lincoln and ESAB sites and write down the competitive products. The new equipment must have built in wire feeder and deliver a minimum of 250 amps (good spray with 035 wire) I would  go to E-Bay and other web sites that offer second hand MIG equipment and look for those products or any other complete MIG package (wire feeder / gun included) that provides 250A or greater weld current. Don't get sucked in to buying new weld equipment that delivers less than 200 amps at 60 % duty cycle. Good luck Ed


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weldability and filler metal selection is for these extremely complex alloys based on the carbon content. Least problems with 
carbon < 0.06% wt. (410 NiMo) Typically you match the base with a similar filler and weld the 410 NiMo steels with the same concerns for low alloy high strength steels. Steels with carbon >0.06 to 0.3% C wt. have decreased weldability with greater concern for cracking and the need for specific pre/post heat treatment. Some of these alloys will be welded with austenitic or nickel alloys. Good ref book on this subject "Welding Metallurgy and Weldability of Stainless Steels" by Lippold and Kotecki  from Wiley Interscience

txtReplySubject:
RE: filler metals for welding 400 series Martensitic Stainless


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The N stands for "Nitrogen" which is added to stainless to improve strength in the ambient to cryogenic temp range.


txtReplyBody:
Try ESAB and Kobelco for best stainless wires and dont use the 10% CO2 it will weld great, however you will increase the weld strength and lower the ductility, use 20 to 25% CO2


txtReplyBody:
Dave I believe that if you take an approach to steel or stainless or any alloy welds in which you approach all welds from a process control perspective then the reality is the alloy composition is not that important. In other words if the application has a weld consumable and you set the weld to attain 'maximum weld puddle control" (sweet spot in my books) and for multi-pass welds use the logic of always applying weld heat interpass temp control of <300F, the welds are always on the way to being optimum. Of course you have to add in the code or steel requirements for pre /post heat. Life can be simple. Ed


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Both CO2 and oxygen are reactive, the more cO2 and oxy you have the more oxide reactions take place. Manganese for example can increase the steel strength, if you go beyond the normal CO2 or oxy content you create managane oxides and loose some of the potential steel strength. Flux cored is a great example, if you are suposed to use 20 or 25% co2 AND YOU USE 10% CO2, the weldability is great however the resulting  weld strength can exceed the specified yield strength of the flux cored consumable.


txtReplyBody:
I've got a MIG-100 with a torn-up cable and torch I'll give you if your willing to pay the freight.


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not if you are MIG welding, however in the USA auto industry thanks to lack of process controls many MIg welds are made without the weld gas and the plant management and engineers never seem to notice, ed

txtReplySubject:
RE: Robot (MAG) welding without sheilding gas


txtReplyBody:
it sounds like the robots have been pre-timed to work in unison with each with each other to avoid collisions, did you speak to the intergrators about this, ed

txtReplySubject:
RE: Welding Delays  in Robotic MIG Process


txtReplyBody:
Hi Ed,Thanks a lot to reply so quickly. The integrator who ever established this cell is just out of the business. Yesterday one of my co-workers comtrolled the problems by keeping trying to modify Arc End parameters. However, we all know it will be come back again in a couple of months just like it happened again and again in previous production. I forwarded your advice to my boss this morning and we are going to investigate further. Thanks again. Charles


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If you are using 045 wire you would need to get past 260 amps to get out of globular.

If you are using 035 wire you would need to reduce the CO2 to <20% and be over 200 amps.


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The Zues process provided real world weld beniftits the AGA process is a good sales tool


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CMT stands for Cold Metal transfer. The welding wire is moved forwards and backwards with a frequency of up to 70 Hz. It is a Weldbraze process - Aluminum is welded and steel brazed.


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He is insane, if you start on that product you will be out of buisness in six months, point him to the Chrsler story on this site, ed


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If you want pulsed go with OTC, if its  a CV regular power source go with Miller Delta Weld


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Two solutions for optimum stainless welds on 1/8 and the helium tri mix is not required for either. 

[1] Use your argon oxy mix and change the wire size to 035. Set the wire at 500 ipm, range 500 to 600 ipm or 3 oclock position and set 24 to 26 volts.

[2] For reallly good results with less distortion look at the new pulsed power source fom Miller as recommended in the MIG equipment section, use pulsed with 5% CO2 and use an 045 wire. Ed

txtReplySubject:
RE: Out of position stainless (forget tri mix)


txtReplyBody:
Thanks for reply but I would like to know why you say that (technical). sorry if I insist. I know that MIG is the best selection for our. I have read your book several times but you don't mention anything about Self shielding Flux cored.


txtReplyBody:
Ed there is a shortage of helium in the USA now and prices will go very high.Which MIG applications do we need helium for


txtReplyBody:
Jason there is a simple answer to this question.
Helium is not required for any MIG steel / stainless or aluminum application.Apart from increasing the gas suppliers profits helium does nothing that cannot be replicated with process knowlege and the selection of appropriate process, parameters and consumables for the application. I started working with the MIG process in 1961 and have never required a MIG  MIX with helium.


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Read the Chrysler CROSSMEMBER story on my web site under real world applications, ED

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RE: Flux core self shielded vs Mig. "NO"


txtReplyBody:
Ed,
I've been told that the OTC will work great with an OTC robot, but will loose some functionality with other robots. What's your opinion on the SKS power sources? Any information will be a great help. 
Thanks,


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TO LEARN MORE ABOUT SELF SHIELDED FCAW WIRES VISIT THIS WEB SITE UNDER "REAL WORLD APPLICATIONS". GO TO MILLION DOLLAR LOSSES WITH SELF SHIELDED WIRES (INNER SHIELD) I WOULD NEVER ALLOW THE USE USE OF THIS WIRE FOR "INDOOR" APPLICATIONS. USE GAS SHIELDED FLUX CORED OR MIG.

txtReplySubject:
If you want weld quality, dont use self shielded FCAW


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not aware of any major OTC functionality issues, that will impact weld quality or productivity and not aware of the power source you requested data on, ed


txtReplyBody:
Ed, 

The SKS he mentioned is a power supply manufactured in Europe (Germany, I *think*). It is an inverter based unit that has no controls on the face of the machine. If I recall correctly, all adjustments must be made with a laptop.


txtReplyBody:
thanks for info, why do i yearn for those simple weld days <1980s


txtReplyBody:
simply match the tensile strength of the plate with the electrode


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Dean,
We have recently converted several older robot systems to the Miller Auto-Axcess 450 with great results.  Maybe this would be a good power supply for you also.


txtReplyBody:
You need good pulsed equipment. I would purchase a miller 350P < $4000 and use the weld information in  (MIG EQUIPMENT) on this site and you will see a tremendous improvement


txtReplyBody:
Thanks, I've looked at the Auto Axcess, but the cost is unreal! I really do not think that the gains are worth the added cost. I've used them in the past with great success, but I'm on a budget with this project. I think the Miller Delta Weld will work the best in this application. SKS power sources can also have adjustments made on the Q8 controller, but you need to be a rocket scientist that speaks German to understand the things. Laptops are far easier to make adjustment with.


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Of course except with an 035 wire you will see weld spatter even if in the spray current range, > 200 amps, however if you can handle 30 plus volts with an 045 wire its as close to spray > 260 amps as you are likely to see. By the way all the text books in the world that state you cannot get spray with > 20 CO2 are incorrect. Ed

txtReplySubject:
RE: Is it ok to use 25%CO2+75%Ar mig welding HSLA steel


txtReplyBody:
Mike you are not reading my books as intended. In the clock method the weld current is clearly spelled out for every wire feed setting. The current / part thickness relationship / weld travel rate is also spelled out. It does not matter if its 280 amp pulsed or 280 amps spray that setting is going to be used typically on parts > 5 mm. Be paitent, with learning about the process and look at the common denominators, if still havin a problem call me at 770 330 9933.


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Hello Ed,
If the lower arc length (voltage) is prefered because of the part fitup, does it mean smaller diameter wire (0.035") should be the better choice? With 0.035" I can use a little bit lower voltage than with 0.045", right?
Thanks.


txtReplyBody:
Arc voltage does two things it provides the current you need and once the wire feed which is the conductor for the current is set, consider voltage as your arc length and spatter trim. Adjust the volts so crackle sound occurs with minimum spatter. If you use that 035 wire with the 75/25 gas you will get spatter off the end of the wire tip even if the arc voltage is set correct.


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No with a smaller wire, 035, used in the spray mode, to attain the same weld deposition rate as an 045 wire you will end up with the 035 wire at a slightly higer voltage. True spray is not attainable with 75/25 and that 035 wire


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For the all position wires use the E71T-1, 0.052 1.4 mm, wire. Note: If you are having weld slag, porosity or lack of weld fusion issues, consider CO2 instead of argon CO2. Ed


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Contact me concerning Lincoln Power Wave 450 Part or whole.


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Marco incomplete questions decerve incomplete answers. Is this automated, robot manual.Whats the weld consumables and data, all would help. Ed


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You can get  ceramics designed specificaly for horozontal welds. This typ of backing provides   less gap in the lower weld area of the horizontal weld, thus less opportunity for weld roll over. If you cannot find supplier let me know, ed

txtReplySubject:
RE: CERAMICS AND HORIZONTAL VEE GROOVES WELDS


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This tells me your training is not effective, place more focus on weld process training, welders need to know how to set and fine tune the flux cored wires. Use my clock method its simple and it works, Ed


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Hi Mike. Sounds like your possibly using a 8mm groove tile instead of a 6mm tile. Make sure ceramics fit tightly to back of joint. Repeatable Perfect defect free roots 10 meters long are normal  but hard work when using these tiles.
Whats your material thickness  and gap sizes,parameters etc?Ive been using these things since the eighties with great sucess so dont discard them too eary.

txtReplySubject:
RE: hiCERAMICS AND HORIZONTAL VEE GROOVES WELDS


txtReplyBody:
Paul look at the next decade. If you want poor weld performance,if you want to spend millions on maintainence, if you want to scrap the equipment after 48 months, purchase solid state equipment for that ship yard. Or you can purchase weld equipment that cost 25 to 50% less, out perform the electronic equipment, requires minimum maintenance. Select regular CV MIG equipment and be trouble free for at least a decade. Ed


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I would try some 309 stick electrodes, Ed


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MILLER USED TO MAKE THEM I DONT THINK LINCOLN HAS ONE, TRY FRONIUS OR ESAB WEB SITES


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[1] If you want to control pulsed parameters, you must have seperate control of the pulsed peak, back ground and freq. Some pulsed machines provide this and some dont. Do you?
[2] Before you control pulsed parameters you must understand the process.
[3] If you use flux cored for pipe you dont have these problems, Ed

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RE: GMAW Pulsed, NiCrMO-xx , Vertical UP


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1) The paramaters such as peak/background current, pulse duration, frequency etc. are not programmable. The selection of wire type and diameter set the parameters for the machine. Uphill fillet welds in 1/4" ccome out looking like they were welded flat. It is mainly situations such as caapping a flush weld that it is difficult to get the beads to flatten out some. 


2) Some FCAW NiCrMo-3 ? Any ideas on suppliers ?

Thanks for the info.

Gerald


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The control you want comes from pulsed setting parameters you have no control of, thats why more consideration is required before that pulsed power source is purchased. Try Kobelco and ESAB for the stainless flux cored products. Good Luck. Ed


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I qualified  an E-NiCrMo-3 flux core with75/25 ArCO2 to Sect. IX on plate 3G for pressure vessel. never tried it on pipe. It was made what use to be Inco, not sure who they are now.


txtReplyBody:
Forget power consumption it's always irrelevant in weld production cost. Compare your robot equipment /  operators / consumables / rework costs against the resulting production for the life expectancy of the intended applications versus manual weld labor  / consumables cost for the same job.


txtReplyBody:
What about in the case of a new job where production volume is a prediction and rework costs are as yet unknown?
Scott


txtReplyBody:
then use my management engineers book to work out what would have been the manual welding costs versus the robot costs.


txtReplyBody:
Erick if you had been around awhile you would be aware that German and English speaking equipment often dont get along. Remember you had a rigid, German robot that wanted to give orders to a free thinking, consevative often screwed up Lincoln power source. Now that the German robot has been joined to that Austrian power source  the relationship is complete.

txtReplySubject:
RE: German robots and US MIG equipment Issues


txtReplyBody:
This is a pulsed application, if you want weld consistency evaluate both OTC and Fronius pulsed equipment. Ed

txtReplySubject:
RE: ABB robots and not happy with Panasonic weld equip


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I would start out with aluminum bronze which is available as a TIG wire o MIG wire, regards Ed


txtReplyBody:
Hi Ed, Thank you very much for the immediate reply. I enjoy learning so many things from you and your site. Thanks once again. Your committment to the feild of welding is unmatched. May god give a long life and make us utilize your expertise efficiently. Best Regards, Mohammed


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could you butter layer 309 or 312  first


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Try this, set the wure feed at 350 ipm and set 22 volts as the weld start data, Make sure the start time is sufficient 1/2 to 1 second. This is start data you should here and the lower voltage limits the current available at the short circuit start, then call me at 770 330 9933 with the results


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Best wire 0.045 flux cored E71T-1, set at 11 to 12 o'clock, 280 to 350 ipm with 25 volts.


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Using short circuit for a root pass, 85/15 - 80/20 - or 75 argon 25% CO2 are all great short circuuit weld gas mixes. So yes using 75 argon 25 CO2 can be used for both the mig SHORT CIRCUIT ROOT AND THE FLUX CORED. ED Keep in mind for a plant that uses both MIG and all position flux cored wires, the most logical gas mix is 80/20% CO2. This gas mix can be used for the MIG, short circuit and SPRAY transfer and also for all position gas shielded flux cored wires


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[1] fIRST THE CHANGE OF WIRE MAKES NO DIFFERNCE.
[2] Tri Mix has no advantage ref spatter.
[3] Any argon CO2 mix  with 1 to 20% CO2 provides spray with minimum spatter.
[4] With 045 wire you have to be past 255 amps, 035 wire over 200 amps.
[5] If using the correct gas and above min current, the spatter is caused becuase the weld volts are too low,
[6] Any salesman who tells you that you require a tri mix is one step below a snake oil saleman.
[7] Happy Xmas

txtReplySubject:
RE: tri mix or 70s-6 to get rid of spatter?


txtReplyBody:
Good advice from Ed. If you cant get a good spray arc then your power source is to small. In my opinion the only time you should use a short circut arc is when your welding sheet metal. In our shop i tell the guys if you dont spray it dont stay...keep up the good work Ed.


txtReplyBody:
James,
  I work for a tier one automotive supplier and we have recently been evaluating power supplies to replace older ones.  We are using Motoman and Fanuc robots at our facility and have had great success with OTC DP400 welders in your material thickness range.  It produces excellent weld quality and has a very stable pulse process if you wish to use it.  If you have gaps on the 18 gage it can weld stably down to about 30-40 Amps.  We are using it on both bare HSLA and Hot Dipped Galvanized parts.  If welding on galvanized use the pulse mode with 80-20 AR-CO2 and .045 wire.  OTC welders are dialed in at the factory for 80-20 but other 2-part mixes are OK.  The only interface OTC offers at this time for non-OTC robots is and Analog style.  The Fronius welders are also excellent and produce great welds.  I am pretty sure the interface is digital on their equipment and it may retrofit to ABB easier but I am not sure.


txtReplyBody:
How about 0.035 solid wire. Thank you Justin


txtReplyBody:
Get my MIG and flux cored parameter book all the data you need is in it, regards Ed


txtReplyBody:
If the welders forget to change gasses then who's in control of your process?  You really need to take Ed's advice and change to one gas mix.
IMHO
PWC


txtReplyBody:
It sounds as though you get far too much advice from your welding suppier.  I would guess that he/she first suggested the wire change ($$$).  When that didn't work out... had to be the gas ($$$).  Now that the gas isn't the "pixie dust" he/she is going to suggest "a round of inverters for the shop floor" ($$$).  When that doesn't work you'll call your supplier but there will be a new sales dude in the old guys/gals place.  He/She moved on because he/she was such a skilled sales person.
Stop the madness!
PWC


txtReplyBody:
As you know I have yet to find a multipurpose power source that provides both optimum CV and CC for TIG. The Miller 350p is an excellent pulsed MIG unit that can produce alsmost TIG like quality on many gage applications, however TIG provides capabilities way beyond MIG. I suppose if I was to go crazy and open a weld shop, I would want a good Miller TIG power source with AC and HF. I would definately want a Miller 350 pulsed Unit and a 350 to 450 Delta Weld, and thats it. Good Luck Ed

txtReplySubject:
RE: Miller inverter vs miller transformer


txtReplyBody:
HI Edd
      Do you know if the 350p is available with a wire  feeder.


txtReplyBody:
a hot pass is simply the first pass over the root, (a weld that fuses into the root and narrow side wall). As for the weave data you provided, it makes no sense.  Ed

txtReplySubject:
RE: Hot pass  and maximum weaving length


txtReplyBody:
Maximum weave width was a technique to control the heat input with stick electrodes - provided a visual check in the field, rather than trying to record volts/amps


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A lot ot WPS for pipelines had a time limit between root and hot pass because the root was (is?) traditionally done with a cellulosic/high-hydrogen rod (6010).  Given the combination of ambient temperature, metallurgy, pipe strain, the risk of hydrogen cracking was high - adding the second pass  increased the strength of the weld, tempered most of the root pass, and in general reduced the risk of hydrogen cracking.


txtReplyBody:
My plant is filled with Motoman robots using the Hobart Excel Arc 450 (Same as MotoArc 450).  We use .035 L50 ER70S-3 with 90-10 gas.  This welder has 2 jumpers located inside the front panel display on the PC board.  They are located in the top left hand corner.  One is marked burnback and the other is wiresharpening; they should both be enabled.  If you enable wiresharpening you will have to add a 0.25 second delay after the arcoff on all the welds or you will get wire sticks.  This should all but remove any ball which will aid in the arc start.  0.035" wire and this welder are very suseptable to large balls after arcoff if wire sharpening is not used.


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The 312 is not necessary for this steel, it offers no weld benefits as a matter of fact from a weldability perspective its more sluggish than the steel MIG wire. The only thing the 312  offers for this application is higher price. THE 312 is used to weld dissimilar stainless parts and tools steels and for these applications it does reduce weld crack potential


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The nitrogen makes sense, the low helium is a waste of time, just use argon nitrogen and then get the heat you need by adjusting the pulsed parameters. Ed


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I think I have about 10,000 words on the Miller erratic pulsed equipment and tip issues under pulsed and MIG equipment section of this site. I would recommend my self teaching MIG process control book as a start, Ed


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Minimal effect and if you grind the surface which you should no affect. I would use a 70xx electrode.

txtReplySubject:
RE: What affect does flame cutting 550 grade pipe have on the HAZ?


txtReplyBody:
Dan when a snake oil salesman sells something to some one you know, you dont have to respond and prove anything. Many years ago I provided the president of Airgas with the first honest gas campaign provided in North America. In contrast to Praxair, Air Liquide, BOC and Carbonic Airgas told the truth about gas mixes and this company  had a very sucessful MIG gas campain based on  two part gas mixes. Now Airgas dominates the distributor market and the honest approach seems to have dissapeared. Why does Airgas want to promote a three part gas mix for steel welds that do not require this mix, who knows, perhaps its weld process ignorance or maybe they have a supply of helium they want to sell. It's a shame when gas companies keep adding confusion to their customer base. Keep welding with the 15% CO2 it will meet any weld code or quality requirement. Ed

txtReplySubject:
RE: Airgas helium tri gas mix or snake oil?


txtReplyBody:
It may be that all X-80 is not creaed equal:  it could be seamless quench and tempered, or DSAW TMCP plate.  We have had some seamless that had a high alloy content, with a very hard HAZ, and could be susceptable to hydrogen cracking - need to consider minimum preheat and would personally try to avoid any cellulosic rod, but that is just my own bias.  The TMCP material we have used was marvelous - soft HAZ, low minimum preheat..wonderful in every way except price tag!


txtReplyBody:
Steve once you weld, withoit post heat treatment you loose the properties of both materials, so the logic is MIG or Fcaw weld, with good ductility E7XX wires and use low parameters and ensure interpass max is approx 200f

txtReplySubject:
RE: Joining 4130 plate and pipe for high strength


txtReplyBody:
Ed, Thanks for the quick response!  I am a little confused though.  I am required to use a 120 KSI filler to match the strength of the base material.  The weldment will then be post weld heat treated to achieve the required as-welded strength my customer requires.  I agree that I will have to pre-heat the base material and control the interpass temperature as you stated.  When using the GMAW process, what do you classify as low parameters?  Thanks, Steve


txtReplyBody:
I WAS NOT AWARE THAT POST HEAT TREATMNENT WAS GOING TO BE APPLIED. THEREFORE JUST USE THE TRADITIONAL WELD PROCEDURES APPLICABLE TO THE WIRE DIAMETERS. ED


txtReplyBody:
its proper to use the consumables and weld requirements as prescibed by the applicable code and weld procedures. Ed


txtReplyBody:
Why not use a 4130 filler metal. I have been involved with welding a structural component for the last four years. We have had excellent results. The base metal is supplied in the annealed condition. The component is pre-heated to 400F and then subjected to post weld hest treatment. In a few instances, due to engineering changes after th pwht, some minor welds were made and a local pwht was applied.


txtReplyBody:
YOU NEED TYPICALLY THREE THINGS FOR THIS COLD CRACKING, (TYPICALLY IN HAZ) TO OCCUR.


[] medium to high strength steels.
[] RESTRAINED weld joints
[] source of H2o

Using low hydrogen consumables, pre-heat 200 to 400 f, weld only on dry clean materials over 60F and good weld procedures and no problems.


txtReplyBody:
try SAIT or NAIT in Alberta they have very good hands on programs, and for real world weld process control expertise i suggest you look at my training resources at this web site. Ed


txtReplyBody:
You could run up the road to Longview, Texas and check out LeTourneau University.


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If you have a 200 amp power source, use 035  309 wire an argon 25% CO2 MIX AND SET THE WIRE FEED AT 11 O O'CLOCK AT 16 to 17 volts,


txtReplyBody:
Jim it's all explained in my self teaching process control book " Manual and Robotic GMAW in the training resource section of this site. Ed


txtReplyBody:
I think the GM engineer  should be fired, as only a fool provides technical advice on a subject he knows nothing about.


txtReplyBody:
That did the trick. Had to turn the Arc Length trim down to 0 and the wire feed pretty low but it dosnt burn through and leaves a nice little bead. I thought .035 would be too heavy for this material.

Thanks!


txtReplyBody:
My thoughts on this over priced  unit are well documented in the weld equipment and pulsed weld section of my site. For steel / stainlss welds this power source offers nothing that cannot be done just as well with your CV power source, and when this equipment breaks down the cost of the repairs may shock you. Ed


txtReplyBody:
The .035 answer is exactly why you need the book. It is  wrong! Don't waste your valuable time and sanity. Best money I have ever spent on welding equipment and it doesn't use consumables.


txtReplyBody:
Listen to Ed. The shop where i work has 4 of these powerwave units along with about a dozen cv 400's. We run the powerwave units on constant voltage because nobody likes the powerwave setting.


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The weld deposition rates you are attaining are no better than that attained from a low spray transfer from a lower cost 0.045 MIG wire.  Choosing a big wire like this, I would look to the weld size required. If  fillet sizes are < 7 mm no benefits are attained from these wires in contrast to the lower cost, 045 MIG wire.

If single pass fillets  > 7 mm and weaving is not an option then you get the benefits of
[] larger wire, wider plasma weld coverage than a smaller wire, 
[] Note you have to be  using 400 plus amps whereas the 045 wire could match your present deposition with a 100 less amps. 

Your weld settings are too low bring the wire feed up to 210 to 240 inch/min and weld faster. From my perspective I would not use this wire as the welds you are doing NOW could have been achived with the lower cost 045 MIG wires, a wire  which offer a wider parameter working range with weld current less likely to create distortion.


txtReplyBody:
Mark what other source can anyone say but the web, select your topic and add the word welding


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We ran 4x 12" S10S coupons rolling 1G

RMD root FCAW no purge - too hot on FCAW, excessive reenforcement OD and ID and sugar ID

move up to Noon 1o clock and increase speed on FCAW cap looks better but I do not trust that ID has no sugar...It looks surprisingly clean but the feeling on the ID is still granular

GMAW root, FCAW cover purged, looks fine

RMD root, FCAW cover purged, looks fine easier to weld root..


txtReplyBody:
You should contact IIW (International Institute of Welding)or EWF (European Welding Federation).


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info available in the pulsed section and pipe section of this site


txtReplyBody:
i forgot to mention i am using 75/25 gas mix


txtReplyBody:
Steve send me your address I will send you some new flux cored parameter cards I have made that deal with all applications, Ed


txtReplyBody:
Steve by the way the 1/4 is the minimum thickness, weld < 1/4 use the 035 wire,


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I recommmend using CO2 when the vee groove plates are thicker than 1/2, as the increased weld energy will be beneficial in attaining superior side wall fusion,less porosity and slag. Try the kobelco CO2 wire. I would use argon co2 for all pipe applications. By the way I have just completed a unique flux cored training program on a CD that anyone can give, All it takes is five classroom or lunch room hours and  every one in the shop will be welding the "right way" using pipe and plate parameters and techniques that create minimum weld defects. Ed


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Eric question is a little confusing my first thought was spray trans with 035 mig wire, could you elaborate, ed


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Pipe spools that are about 36" long with a slip on plate flange on each end.

Thinnest material is 6" OD X .125 wall tube, they specify a 5/8" thick plate flange on each end. Some spools are .134 wall with a 7/8" plate flange They call out 3mm weld fillets OD and ID.

I think rotate GMAW Short circuit .035 down on ID for a seal pass, then .045 FCAW uphill rotating on backside with a slightly larger single pass fillet...FCAW will be the strength on the back side...Hopefully we can avoid blowing thru the tube.. 75/25 is typical gas...


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dont use short circuit lack of fusion on the flange side will occur the 0.125 wall thickness and small single pass weld enables either a 035 MIG spray with 10 co2  or an 045 flux cored with 25 co2. Rotate pipe weld at 12 oclock.


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Thermal Arc would not be on my list for a pulsed power source, Ed

txtReplySubject:
RE: Pulsed MIG: ThermalArc Powermaster SP ?


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Thank you Ed for your valuable info. 
I was tempted to get this new series Powermaster 320SP/400SP, since I believe you had mentioned somewhere about any pulsed MIG power source released after 2006 would be a good power source.  Obviously not from Thermal Arc.


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By the way I said the pulsed technology finally appeared to provide consistent weld results with equipment made after 2004 however, few weld equipement manufacturers have provided a pulsed power source that produces stable, consistent pulsed transfer,  OTC and Fronius are two companies that are on top of  this technology,  keep in mind that on many applications you dont need the perfect pulsed arc. For your application I would compare OTC with Millers equipment. Regards Ed


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I fully disagree. 
We run Lorch Saprom 320 and it is excellent machine. Definetelly better than Fronius TPS 2700 (we also have it) in aluminium welding. Unlike Fronius, it has "double-pulse" feature and is excellent for thin al-sheets. Also Lorch offers 3 years warranty unlike Fronius with 1 year (at least in Europe is so).
I suggest you to try both machines and compare them.


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Again I suggest you try the OTC versus miller.


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Now your weld is far greater strength than the parent metal, as the weld shrinks it imparts great stress on the weakened HAZ.

txtReplySubject:
RE: When welding .25 A36 to .38 A36 steel with ER90S .045 and 92 Ar/8 Co2 mix,


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Alum today is mostly about pulsed welding. Pulsed welding with that 1.2 mm wire. In your pocket you have 4 simple settings for every aluminium application. 100 - 200 - 300 - 400 ipm wire feed. and 22 to 26 volts. Start out at 200 ipm 23 volts and if to hot go to 250 ipm 24 volts. If too cold go down 50 ipm. Use a fore hand technique and set the trim (volts) arc length as short as possible. You get the picture. Thats pulsed alum welding, and as you can see there is not enough of a subject to write a book.


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at work we have a puled mig (miller 350p) but i perfer the standard mig mode. is there an easy way for judging the wfs from 1/8" up to 1/2"?


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i forgot to mention we use 3/64 5356 wire at the shop with a python push/pull gun!


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you may want to add a piece of steel to brace the cracked area, and yes all frames are weldable


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Is there a certain type of weld that should be used on the truck frame?  stick, mig, tig any special one
Thanks for the info


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Eric my process control books, VIDEO and training resources are all youu need for MIG and FCAW


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The bottom line Jim. On your clean application, no WELD benefits from the  METAL CORED  stay with the lower cost,  solid MIG wire, ed


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Eric,
I've been providing welder education for production mig (GMAW) welders, witha focus on process control, for years.  I'd be happy to talk with you about welder training at your facility.
Check me out online at www.PWCInspectionService.com
PWC


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To ask me that question is like asking the pope does he eat fish on Friday, you know the answer. and if not visit the MIG equipment section of this site. Ed


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You provide minimal weld data which does not help, with alum porosity look to the obvious, lack of gas flow, long arc length not using the fore hand, contaminated weld surface


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It would be logical that on this high duty cycle application, you would use a water cooled gun. As for the best water or none water cooled gun available, talk to Tregaskis. By the way this sounds like a 1/16 E70T- application, the slag keeps a lot of the heat off the nozzle and the hot welds have the slag protection. Ed

txtReplySubject:
RE: Best MIG Gun for for hot 0.045 application


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Ed I doubt you are seeing excess oxy, remember we commonly  weld with argon 5% oxy mixes, i suspect you are having gas flow or part contaminate issues, ed


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Weld repairs here are common, and aftermarket repair plates for Chevy trucks have been sold for years. I defer to experienced welders for what ros/wire to use, but extra reinforcement is your friend.


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There is no problem with the 92-8C02  gas mix as there is no concern about carbon pick up when welding stainless to carbon steels. If welding stainless to stainless the CO2 content should be <5%. Ed


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Neither, the most cost effective choice 30 years ago and still  today is SMAW ROOT  AND FLUX CORED fill.
If you have no choice use SMAW ROOT / FILL


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Keep in mind the products you talk about are likely older than you. What you bring up is an inherant part of the industry we are in, an idustry which needs a lot of help.


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[] Both gas mixes great for spray. Go from 10 to 15 % and you will in the spray mode need to increase the voltage from 1/2 to 1 volt. (more energy from the 15 CO2)
[] If welding multipass sprAy welds and the welds are too hot, better puddle control from the lower energy 10 CO2. 
[] Argon 10 co2 is not suited to traditional short circuit while 15 CO2 is.


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It's a simple answer. If your root welds lack any evidence of oxidation with your procedure, which I DOUBT than your procedure is OK. However I know and you know that oxidation is evident, therfore the corrosion resistance is decreased and the crevis corrosion potential is increased, and thats that.


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yes, that's why we use nozzle cleaning stations and anti spatter spray in the robot cells, ed


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Prax is pushing this but I also doubt the root is clean eventhough it does not look bad.


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shawn you open up a can of worms with this question. I will provide a little free advice.
 
 [] As the Twin wire system is typically more
 costly than a robot, its often more logical and much more cost effective to "if possible" add another single wire robot the robot cell.
  [] If your mig weld personell are playing around with single wire MIG controls, how are they going to handle weld issues with a far more complex Twin wire system.

  [] Twin wire is only benefical on specific welds, and keep in mind while the average weld deposition rates with single wire MIG are in the 10 -14 lb/hr range, its possible with MIG to attain 18 lb /hr on specific welds.


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ed thanks for quick reply. Whos twin wire equipment would you recommend?


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there is oime nly one twin wire mfg at this time that I would recommend, "Fronius"


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Wouldnt it be more cost effective to just use a bigger wire?


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Dave there are deposition / current limits to wire sizes > 0.045 so the answer is no.


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Mike I would definately look to pulsed if i was having heat or slight spatter issues on parts
< 8 mm. I would look to spray transfer when weld fusion needs to be improved especially on parts > 6 mm. I would definately use pulsed (045) wire on all stainess parts < 8 mm.


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Forget the RMD and STT. Both these transfer modes are beneficial for MIG welding a pipe root. These two transfer modes  are included in weld equuipment that can cost $600 to $12000. I would recommmend from Miller the 350P pulsed power source. This unit  will provide actual weld benefits on your thin applications and this power source including the wire feeder should cost less than $4000.


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If you use a paste flux or special filler electrode that promises you don't need an inert purge gas for stainless root protection, beware. With these products you will end up with a  ID weld that shows evidence of oxidation or has residue left on the root weld surface. The problem is further made worse by multi-pass welds. I would only use the products mentioned, if an engineer has prequalified the weld and for the application.
As my od buddy Walt Sperko states.
The only way to ensure that the inside
surfaces of welds made in stainless
steel or any other corrosion-resistant
material is free of contamination
and excessive oxides that may cause
corrosion of the pipe is to deliver a
shield of an inert backing gas that sufficiently
displaces the oxygen from the
inside of the pipe.


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what is SCS AND why would you use argon / oxy for any steel application?


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On of the most important attributes for a job shop is the time required to program a welded part. I believe that an ABB robot will be programmed approx. 50% faster than any Japanese robot. I also believe the Swedish ABB robots have many soft ware and hard ware benefits in contrast to all Japanese robots. Also I believe when the robot is used with rotary positioner the ABB robots will maintain closer tolerances to the weld joint, Ed

txtReplySubject:
RE: best robot for a iob shop is an ABB robot.


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JP: For weld automation or for any critical, consistent quality pulsed welds I would purchase an OTC pulsed power source. The best value for your shop welds would be the Miller 350P. This data is in the MIG equipmet section

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RE: best pulsed power source for robot and manual welds


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According to www.scsprocess.com "The SCS process takes ‘down & dirty’ hot rolled black and gives it a beautiful, highly paintable CRS surface. It is clean, consistent and powerful in its simplicity. The heart of this patented process is a controlled “brushing away” of all surface scale except for a thin layer with desirable attributes." SCS stands for Smooth-Clean-Surface. The SCS process can be used inplace of your standard pickle & oil process.  The steel come in clean with no residue.  From our previous experimentation with it we had problems with spatter sticking the steel.  According to the manufacturer they recomended using Argon and, 3-5% Oxygen mix.  Instead of the Argon and 15% C02 mix used during our test. This is supposed to significantly reduce spatter.  The benefits of the material according to the manufacturer are, clean oil free materials (less smoke), faster laser cutting time, lower material cost, and excellent corrosion resistance.


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We ran some tests this past week with the SCS material.  We found that the recommended argon, 5% oxygen gas to create very poor welds in short arc mode.  The welds would break right at the joint. It did weld nice in spray.  The spatter was significantly less with the oxygen mix.  We determined that if we were to use this material to get a good weld it was best to use our current process and be more liberal with anti-spatter spray.  We all had concerns about the steel manufacturers recommended gas and settings. It was a real learning expierence for all parties involved.  With more & more pickelers going under we felt it was important to look into EPA friendly steels. I was wondering if you had any suggestions on parameters and gases to try to reduce the spatter on this different material.


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very normal, its a gas mix that been around since the nineteen sixties, good for very thin gage < 16 gage as it allows low voltages and good for spray or pulsed, down side is it can cause excess root porosity and lack of weld fusion on specific parts > 6 mm due to its finger penetration profile, ed


txtReplyBody:
Mike any 15 cent plastic flow gage set on the end of the gun nozzle indicating a wide range flow of 25 to 40 cuft an hour is all you need. Someone needs to get their focus on the real cause of weld issues. Ed


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stop wasting your energy on MIG gas  tests that were done 50 years ago, call ed at 828 658 3574


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The intensity of the pulse3d arc is likely less, than that you had with the spary transfe. The arc plasma helps break up the alUm skin. WheN the voltage is too high (arc length too long) the skin (oxide) is not removed fully and turns to a black soot. You need higher pulsed parameters, (frequency or peak) lower arc length (lower trim volts) or slower weld speeds

txtReplySubject:
RE: black soot on pulsed MIG alum surface


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The prime cause is the start "voltage" setting, there are other cuases related to the weld end data and burn back data. For data that eliminates this condition I recommend my Robot Process Control book, regards Ed

txtReplySubject:
RE: Ed what is the  cause of wire burn in a robot cell?


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Fraser: Thanks for kind words.  This contact tip isue is common, it's usually a  distraction or crutch for plant people who typically lack the abilty to get to the real root cause of their daily  weld issues that result from burn backs, poor start and end data,incorrect wire stick outs or wire helix issues. The contact tip needs to be approx -.007 to 0.01 larger than the wire. If the wire runs through the tip and it snags, it's too tight, if it runs through and makes consistent contact its fine. If the tip bore is not the correct size, (check with drill gage) change your tip manufacturer.Keep in mind also that  hot wire will expand durining welding. Also when you purchase smaller tips,  remember that  with today's inconsistent weld wire quality the wire max OD is frequently on the plus side. The other possibility is the tips you purchase are made in China (wire sizes and tip sizes are today greatly  influenced by sub standard products made off shore) Good luck. Ed


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this question sounds more like an asian puzzle. The bottom line when welding thin to thicker plates, treat the weld requirements reference the thiner plate. Ed


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Pipe welders may think that pipe welds offer the greatest weld challenge, however this application does not even come close to the challenge of all position vee groove welds in a ship yard.

The pipe welder can use FCAW for fill passes and the easy to use MIG RMD / STT for roots. The pipe usually has a clean, machined 60 degree grouve with 2 to 3 mm root. The ship welder may have a rough cut, 40 to 50 degree vee  with  root gaps that vary from 5 to 25 mm. These gaps may have a ceramic backing which when welding more than a 7 mm gap  stretches the welder's skill requirements as the flux cored  weld bridges the none conductiive material. The ship  welder is out in all weathers with minimum protection. The ship welder may weld jonts 20'  in length and may have to make the welds from a shaky scaffold.

 Most ship yard welders can  weld the vee groove in a 360 degrees, pipe weld, whereas most pipe welders would not know the requirements to place that FCAW root weld across a ceramic.


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The Airgas Marketing Gas Manager knows better. There are a number of argon CO2 mixes that will produce optimum MIG weld quality and spatter free welds which will meet any quality requirement. Perhaps the reason Airgas wants to sell industrial gas mixes that have helium in the mix, is Airgas possibly owns a helium source, and lets face it  If you own a source of  gas you have to figure out ways to sell it.


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Ed,
I partner of Marco,we have bancroft welders( semi automatic welders ),but when start the arc the WFS is high and give me an cold start.We use a 0.045 contact tip of consumables Do you thing that I can adjust the wire speed  for reduce this start.I know that others equipments have the conditions of start low and lather increse the speed.Thanks for your help


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Just to add, the travel speed ranges from 250mm/min to 400mm/min

txtReplySubject:
RE: Porosity in A335 P22 pipe using GMAW


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Ed's Answer: Its hard to believe 30 years after the introduction of steel and stainless flux cored wires, products by the way that have only ever used two gases, argon CO2 and CO2, that somone in a position of responsibility in a North Ameicane weldshop would try to qualify stainless flux cored welds with the helium tri mix. With this highly inert gas, you will have extensive lack of weld fusion, porosity and slag entrapment, you will also have welds that have exceeded their maximum strength and lost ductility. Tell the inspector that if he wants to stay in welding , that weld process expertise is a part of his job requirement. If he had invested $80 in one of my books he would not have caused weld issues that will cost thousands to repair.


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the fact that the  part of the 400 series weld in question is attached to a "mild steel part" makes that part unsuitable for high temp service or the weak link. It like being concerned about the corrosion properties of a weld when welding carbon steel to stainless. You know from a corrosion  perspective that the weld will not have the same corrosion protection as the stainless.

txtReplySubject:
RE: Mixed Metals - 409 and 426 SS to mild steel


txtReplySubject:
RE: Welding Joist hangers to Steel Wide Flange Beam


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My mistake- flux is OP121TT, not "141". Thanks.


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Typically in a none heat treat application with this grade we would use a  E7XXX or for some grades an E8XXX electrodes


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I guess my main concern for welding 409 or 426 to mild steel with 309L is that the weld has good integrity, that it doesn't have some unexpected crystalization property that causes it to fail under normal engine and road vibration. In this case it's at the back of the vehicle and heat is not extreme.


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It should have been a separate question about the warnings not to use 309 for welds above 750 or 1000F. What happens to it?


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if corrosion is not the issue than at the end of the day do a macro, look to the fusion


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What kind of 'poor quality'?  Be specific.  The first two things that come to mind are to change the electrode tips and make sure to purge the gas for several seconds.


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I purged the gas for 60 seconds this morning, ran a part and the welds will skip, and look ropey, After that I created a routine and ran a 12" bead across a piece of flat steel, ran another part around and the problem went away, The contact tips were new.


txtReplyBody:
to be able to pin point the root cause 0of your issue, write down what you believe are all the variables that can affect that root cause and reply, the list should have at least 20 variables. By the way why are you welding with that 0.035 wire (a key variable to inconsistent weld is inconsistent wire feed) when its possible to weld thin gauge with the 045 wire that costs less and has superior feedability.


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On these thin applications for both steel and stainless, try both straight argon and my argon 2% co2 mix, regards Ed. ps visit the MIG gas section for extensive gas data.

txtReplySubject:
RE: Pulsed MIG gas for welding very thin gage:


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From a weld parameter perspective you wont see a difference as both mixes require low voltages. From a a weld quality, meaning attaining consistent side wall fusion, I would be very concerned that with so much weld done in the vert down position that you will have serious lack of fusion issues. Do you carry out frequent cross sections (macro)of your typical welds and examime your side wall penetration? If I was doing vert down MIG welds I would be using an 035 wire approx 500 ipm and 24 to  26 volts. I would limit both the part thickness and fillet weld sizes to 3/16. Ed


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For this super MIG / FCAW duplex application, go to my gas section and scroll 3/4 down and use my duplex CO2 nitrogen mix for the MIG root. With the RMD root, I would first try straight argon (root only) and compare it with my tri mix.  For the flux cored fill its likely you will be using an argon 20-25CO2. Let me know how you do. Ed


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can you tell me about the gap dimensions and edge prep condition, can you MIG RMD or STT? If you have to use ceramic can you use gas shielded FCAW?


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No, we cannot afford STT or RMD. The gap is designed to be around 6 mm (wall thickness 12 mm, pipe fixed), we expect gap to be 4-8 mm at the end. We are allowed to bevel the edges as we consider it is the best. If we use ceramic tiles, we can use ER71T-1, but we are afraid if it would pass strict x-ray control. If we use ceramic and FCW, we concern about bad welds in the root, and slag entrapment in the root. Therefore we think about alternative, to use cellulose for root and FCW ER71T-1 for the rest.


txtReplyBody:
if your theory was correct no weld on a ship would get past an x-ray. Use the flux cored for the root over the ceramic. By the way my flux cored training CD has all the optimum settings and techniques for the root, fill and cap passes


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I cant speak for everybody in the shop but when I weld I pay particular attention to the puddle to make sure it is digging in without undercut and also    "wetting" I believe is the correct term. Haven't had any fusion problems but occasionally someone will get cold roll because of incorrect voltage setting.


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Sometimes the weld will just walk up onto the vertical plate and stay there, sometimes it goes to the bottom.  I have the driveroll tension set correct, also the wire straightener set correct, and we are using a u grooved drive roll for 1.2mm wire. I am about lost as far as what to try next.  I was looking toward purchasing your book for robotic weld practices, but the description mentions only carbon and stainless steel, which would not be very helpful for what I am doing.  Sorry for the long winded post, I hope you can offer some guidance.  Thanks.

Clay

txtReplySubject:
RE: Welding thin sheet aluminum with a robot


txtReplyBody:
clay a number of issues here call me friday after 3 pm eastern time, 828 658 3574, ed


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I do not deal with the SMAW process, sorry Ed

txtReplySubject:
RE: Chineese Q235B  Steel - Weldig Proceedure


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it does not do it any harm, but its also not necessary. Ed


txtReplyBody:
Frank this question is answered in my pulsed MIG and short circuit section of the site. STT is easier, RMD does the job with a more logical cost effective power source


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Dave as you are not cutting each weld and examining the weld cross sections, you are not seeing the lack of fusion issues. Your shop weld pracftices are poor, I would not allow them or the gas used.Ed


txtReplyBody:
Ronald, your english is excellent. I would look to two causes for your problem.
[1] Your MIG gas has more than 20% CO2.
[2] As with many S. American wires your  weld wire does not have the chemistry  suited to spray transfer.Ed


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A third possibility is something has gone wrong with the power source and you are not getting current you believed you were getting, check volt / amp out put.


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if it's carbon stainless or low alloy steels "no influence" Ed


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If you placed all the BS in this industry in a pile, Mount Everest would look small. You can use either short circuit or the pre programmed  pulsed program for this common stainless application without concern for wave forms. You also need to get rid of the Helium Tri Mix. I would suggest a short lesson on weld  process controls and touching up a few robot points and you will be back in buisness without riding a wave.


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Good question. The answer is in the pulsed MIG section 2.

txtReplySubject:
RE: The reason for arc instability with high speed pulsed mig welds?


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For medium heat application, the use of solid aluminum, copper and brass is common and of course having them placed as close to the weld as possible is important. A coating on these components of anti-spatter grease is also help full. For higher heat applications, taking the same metals and flowing water through them works well.

txtReplySubject:
RE: Using heat sinks to weld steel components


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As this bolt is quenched and tempered welding on it lowers the strength of the bolt. To stop the bolt spinnining it may be more logical to weld a small piece of steel on the plate either side of the bolt.


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This question is covered extensivily in the MIG gas section.Ed

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RE: Welding mixed stainless on robot, want to change gas


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The best process for this is the pulsed MIG process. My site has extensive info on the requirements for MIG welding duplex. ED


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Josh the answer is a simple one. There are no real world, MIG weld benefits that will justify the purchase of pulsed equipment for alum applications in this thickness range.

txtReplySubject:
RE: Do I need pulsed MIG for my alum applications


txtReplyBody:
you are just about there, once you go smaller than the diameter of the MIG wire utilized, look for trouble. Also keep in mind the weld  rules change with the joint. Thin gage lap welds can take more weld heat thah fillet or butt welds. Also if you can use a copper heat sink, you can also go thinner. The modified short circuit modes are also beneficial for the very thin parts. Look at the Fronius web site under CMT. Regards Ed.

txtReplySubject:
RE: Min. thickness of Aluminum part at pulse welding


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With stainless STT MIG you will be well served with the argon 2% CO2. For the  flux cored fill, argon 20 - 25 CO2. If you use the high CO2 for the MIG root you add to the carbon content of the MIG root. Ed


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we used them in the Phily ship yard, they had the worst durability and highest maintence costs I have ever seen with MIG equipment, and in contrast to the lower cost, more durable North American CV equipment, the slope out put (current out put) was inferior for the flux cored wires. Ed


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Thank you very much for these details!!!


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Last time i saw someone use water cooling on welded 400 series parts I  saw cracks in the welds. Let the welds cool in a controlled manner, YOU COULD PLACE THE PARTS ON A RACK AND USE A FAN.

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RE: quenching or cooling of 16 ga ferritic S/S 430/439 tank


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Most of the AWS MIG process data I have viewed has minimal pratical significance.


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I guess that i should add that there is no code I am concerned with.  This is an issue of discussion on what joint configuration and processes are better for this scenario.  The material would just be mild steel.  I hope to add your viewpoint to a long running discussion.


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If there is no code requirement is a back up bar allowed. If a rolled back up bar is allowed THAT SIMPLIFIES THE PROCESS CHOICES AND JOINT DESIGN CHOICES.


txtReplyBody:
Ed, No backing is allowed.  Although, I take from your comment that it is a better way to go.


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Bottom line is SMAW root. All position 045 E71T-1 flux cored for fill. I would use a 60 vee bevel, unless you can machine J groove.


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Thank you sir.  We all appreciate your dedication to the industry.  Hope 2008 is very good to you.


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It's more sluggish than 308, which increases the opportunity for lack of weld fusion


txtReplyBody:
Apart from the common contamination issues, the prime reasons for pipe weld porosity are;
[1] Too much gas flow made worse by vee preps. set 25 to 35 cuft/hr
[2] weld beads too thin, weld bead freezes too fast, increase weld energy, use higher wire feed settings, slow travel speeds, reduce weaves and any osscilation techniques.


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For your MIG applications there are very limited, real world weld benefits from the more costly pulsed equipment. I would purchase  23 regular CV MIG power sources like the Delta Weld 350 and one or two pulsed power sources (350P) for those applications that can benefit. With the thousands of dollars saved, spend a few hundred dollars and train your operators on how to get the best from traditional CV MIG equipment without playing with the weld controls.


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Most crane booms built in the USA  have specific AWS weld guide lines and standards. Typically the AWS STRUCTURAL CODE is applicable, and a standard MIG or FCAW plate weld test is applied for flat position or vert up welds. I  want to point out to any weld personnel who are nervous about weld tests, that all AWS and ASME MIG and FCAW weld tests are greatly simplified when you gave the ability to fine tune and optimize the MIG / FCAW paramerers selected. Know your process and consumables and utilize the correct techniques and you are on the right path to pass any weld test. Ed


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Karen thanks for kind remarks. Welding galvanized steel to stainless, same rules apply as welding none coated steel to stainless. Typically you would use a 309 filler. With MIG  use the regular MIG gas you would use for the carbon steel. I would completely grind of the galvanized surface off at least 12 mm to minimze galvanized  pick up. I would use low to moderate weld settings.  I would dye pen the weld and also do a cross section to  look for defects. I would expect some porosity. Another common practice is after the first pass weld is complete, take a grinder to the weld and remove the weld then weld again. Good luck Ed.


txtReplyBody:
What is your typical application? What is the wire size and average weld current used and what is the typical weld size and weld length and in an hour, how much of that time is the robot arc on time?


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QT 100 is an Algoma Steel (ASTM 514).  In  USA ASTM 514 is  a >100,000 PSI plate, dual certified (Structural and Abrasion Resistant)  This plate has a tensile strength of approx. 136,000 psi. This steel is typically has high approx .28. Use a high strength flux cored or MIG wire in the ER100S-G or ER110S-G. Use  low to moderate weld parameters. Maximize the single pass fillets to 1/4. Pre Heat / Post  Heat and interpass max temp of approx. strongly 250 - 300F degrees for 18 to 25 mm thickness. Avoid welding in drafty location. At weld completion I would use a welding blanket for a slow cool. Important.Avoid excess joint restraints. I would typically when pre-qualifying this application ensure the completed test coupons meets my internal weld quality and plate mechanical requirements

txtReplySubject:
RE: post weld stress relief with QT100 material


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Your heat treat is not a requirement of the electrode its a requirement of the base metal and applicable weld code to that material. When you get that info google the grade and you will likely get buried in weld data.Ed


txtReplyBody:
Hi Paul,just hook up with your current plant cooler system if needed. The water-cooled guns will cause water leakage during production. Think about Ed's question and then make a decision.


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try a miller 350P pulsed power source Use the stainless pulsed mode and an 0.045 WIRE and argon 2 CO2

txtReplySubject:
RE: Mechnized hi speed hi quality s/s weld


txtReplyBody:
Thanks Mr.Craig we will give this a try tomorrow we were going to go from .035 wire to .025 but we'll try the .045. Thanks again for you're valued input. Would you explain the logic behind going up in wire size on this thin material.


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Its not about size, its about current. with the pulsed process and 0.045 wire you can use very low current < 50 amps and maintain a stable arc, that is if you purchases a good pulsed unit.


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Thanks you very much Mr. Craig,we made a sample weld today with the .045 wire Miller XMT350 w/ optmia pulse control argon 2%CO2 argon purge on inside and it came out perfect.I'm going to order a set of your books. I have a copy of Gas Metal Arc&Flux Cored Welding Parameters from a simniar you gave in the early 90's in New Orleans is there a new version of this book or is the info in it still the same. Thanks again


txtReplyBody:
YOU MAY WANT TO LOOK AT THE MANAGEMENT ENGINEERS GUIDE TO MIG AND THE MANUAL AND ROBOTIC WELD PROCESS CONTROL BOOK, REGARDS ED


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MIKE IF YOU CANNOT FIND A SUPPLIER ON GOOGLE, IT'S NOT OUT THERE. REGARDS ED


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Dual shield is simply an Alloy Rod (ESAB) gas shielded flux cored product. Its a good product when gas shielded flux cored wires are warranted. Its no better than a lower cost MIG wire if you are welding clean steel in the flat / horizontal weld positions.


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It has no effect on 300 series, it's little more than a marketing gimic origionally from AGA Sweden. Take a look at the MIG gas section as to why the helium tri mix is also a awaste of time


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Apart from gas section, also check out the duplex and stain sections for info on this gas


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do you think I'm correct with my concern regarding ther potential of ferrite depletion when using the gas mix previously mentioned for welding root passes in 304 stainless steel. I understand the benefits when welding the duplex and super-austentite steels


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ANOTHER MYTH. THE REASON HE SHOULD NOT USE ANTI SPATTER IS IF YOU KNOW WHAT YOU ARE DOUNG WITH MIG PARAMETERS, SPATTER IS NOT AN ISSUE. ED


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NO IT WOULD BE A COMPLETE WASTE OF TIME. ED


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Good welding advice but from a code compliance stand point... maybe not so much.
If your welding needs to meet ASME requirements than changing that shielding gas type/mixture/or% requires qualification.
You should run a PQR just to cover your bases.
PWC


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DOUBLE VEE GROOVE 55 DEGREE JOINT. 6 TO 8 MM GAP. CERAMIC BACKING. 1/16 E70T-1 FLUX CORED WITH CO2, SETTINGS IN MY FLLUX CORED BOOK  EVERY TWO PASSES TURN PARTS OVER. PRE - HEAT AS REQUIRED FOR 514. ED


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Go to the pulsed mode section of this site. Regards Ed

txtReplySubject:
RE: Pulsed on 400/ 300  seies stainless?


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i am in europe at this time so not available by phone, i will try to call you this week. my e-mail is ecraig@weldreality.com, regards ed


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Harry its in this web site under Ed´s Welding Applications Section. regards ed


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THIS IS A RELATIVELY SIMPLE OPERATION USING PULSED MIG AND STRAIGHT ARGON, ED


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AS optimum welds need all the current the power source is supposed to deliver, its logical when possible to clamp the ground to the part within close proximity to the weld. Screw type grounds are better that the common spring loaded ground.


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Is there one of your books you would recommend to assist in finding good welding parameters?


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as overlay requires special dilution requirements you will noty  find the answer in a book, however for $375 my standard advice fee i will provide you with what you need, ed


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you know the answer to this, if they accept SMAW HOW CAN THEY NOT ACCEPT SMAW?


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Pete its unfortunate your company gave up the excellent performing Delta Welds for the inconsistent Miller Axcess weld equipemnt. The problem is definately with the Axcess, its commom in many locations i have seen the problem in the USA and Europe. Miller knows about the problem yet seems unable to fix it at this time.


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i can do the training at your facility or make other recommendations, will be back in USA next week call then 828 658 3574


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We are just a small shop (3-4 people) but I might be able to get interest with other similar companies to defray costs (although the costs might be reasonable to us regardless). AWS certification for these limited mig processes would also be necessary for insurance purposes. 

I'll call as you advise so we can discuss details.


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My preference would be the traditonal short circuit and controlled globular modes using an 0.035 1 mm wire. When set correctly you will produce spatter free welds and the SC mode will deal with any gaps. From a weld productivity perspective the results will be similar as to that attained with the 045 wire and pulsed.


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herb i take it you did not seetha $189 training programs in the book section of the site, ed


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Joel I would consider a J groove when weld steels and stainless thicker the 3/4 > 18 mm. Ed


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[] 6005 is a medium strength, heat treatable alloy with good corrosion resistance.
[] 6005 has medchanical properties found between alloys 6106 and 6082 and typically 4043 is used for welding.
[] 6005 has good extrusion characteristics. 
[] It provides a good mill surface finish.
[] Its difficult to produce in thin-wall complicated shapes.
[] 6005 tube has very good bending properties.

So the bottom line if the 6005 parts are avaialble they should be a good choice for your bike project. Regards Ed


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Its nice to see someone who actually looks into things before embrasing a new process or technology. If you are using rotating weld joints and good weld preps I would highly recommend the tandem process. Of course it pays before utilizing this technolgy to know that you have attained at least 15 lb/hr with the single wire and completely understand the single wire process. If thats the case i would look at Fronius. GOOD LUCK ED

txtReplySubject:
RE: Views regarding  Mig Tandem Welding Process


txtReplyBody:
Hi Ed

Thanks for your feedback and advice . I certainly intend to do my 'homework ' regarding our current process before making any changes.
I guess that ordering your training course material would be a good starting point, and perhaps we may have the pleasure of meeting you at a later date.... the South West of France is certainly more appealing than most of your other 'exotic' American locations.
Cheers.


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The chrome in the weld area should go as it may promote micro cracking.


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To ofset the chance that chrome gets into the weld I would also consider using a 309 or 312 wire


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Anthony use the optimum WF settings in the alum section of my site. If i was using a steel or stainles liner for alum to minimize the blockage that can occur from the alum dust particles, I would make sure the liner is a flat steel liner or if its a wire coiled liner make sure it its a couple of sizes bigger than the weld wire. For that 045 wire I would use a 1/16 liner, and blow it out once or twice a month. By the way the low to optimum Alum spray WF settings are also the optimum pulsed WF settings. With 045 alum wire and pulsed you will likely use 21 to 25 volts Start out at 23 to 24v. Good Luck Ed


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ITS NOT GASLESS MIG, ITS GAS SELF SHIELDED FLUX CORED WIRES USED WITH MIG EQUIPMENT, VISIT THE SELF SHIELDED FLUX CORED PART OF THE SITE. IF WELDING A CHICKEN COOP ITS FINE. ED


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I would suggest you get a job with a company that can build it's products to it's  drawing design dimensional specs. These companies are uncommon but you may find one. Ed


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treat it as you would any carbon steel weld made with a 7018 stick or 70s-3 mig wire


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I think if they listen to you about eliminating the anti spatter and 70s6 wire. they would be fine. It's nice to see a company put the coating on after the weld This must not be an automotive part.

txtReplySubject:
RE: Post Weld Preparation for Hot dip galvanizing


txtReplyBody:
there are hundreds of electrode for steel recommendations in the steels  section of this site. ed


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The bottom line is no. It's simply the way the companies make the wire and market the wire. There is differnces between the wires in cast helix, and weld transfer but those things have nothing to do with the coating. For example National Standard makes uncoated wires and Lincoln makes the coated wires. There are many benefits to using the Lincoln L-50 wire in contrast to the Nat Standard wire. Subject is covered under the weld equipment and consumables section. Ed


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Yes using 8018 or 7018 depending on application, use and code requirements


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You can get a build up of slag islands which could be a concern, however its more important for the welders to stop after each pass and if necessary  use a grinder to ensure a concave clean surface. I suspect that lack of side wall weld fusion is your major weld issue.


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but there isn't any option of short circuit weld mode from Miller Axcess Pulsed power source if we turn off the pulsed mode.


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The stub out is not a normal function with a tungsten arc length correctly established. There is no reason why the tungsten should touch the weld unless;

[] The alignment of the orbital equipement is not correct.  Before welding run the tungsten around the part and check the tungsten tip to work distance. 
[] If alignment is ok, check to see if the stub out occurs in the same general area, if so 
check your weld size is it too large at  the point of the stub out? Is the weld at that point too fluid and buiding up touching the tungsten.

If arc length is correct and weld is too fluid a slight 5 to 10 % increase in the weld speed at the problem area  may help..Let me know what happens. Ed


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You missed the best and easiest process to use flux cored. I would TIG root and 045 flux cored fill, if you want inferior weld fusion go with the pulsed


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haha, there is no FCAW wire, the material is "secret" we wish we could go FCAW...my only choices are GTAW, GMAW.  I am getting coupons and will weld with a close FCAW and sell it


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Why would they struggle, when there are many resources available including those at this site that tell you where to set the parameters for the 052 wire,


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With AC welding we get both REP and REN. 
With REP (electrode positive)the majority of the electrons will flow to the tungsten tip while the larger positive gas molecules hit the alum surface breaking up the alum oxide skin. Unfortunately REP sends to many electron to the tungsten tip and the heat build will melt the tip end. To avoid the tip damage, with all TIG welds we use REN (electrode negative)in which the electrons are driven away from the tungsten to the work. With AC alum welds and a balance control its beneficial to use an arc with a little amount of REP added, so set 80% REN and 20% REP for it cleaning benifts. Ed


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Youn need to check your real world wire feed rate and check your weld current and voltage if posible with metert. The data you provide would provide would typically provide spray, however as its a Lincoln product you might want to verify that the data you provide here is actual. My process control programs place some emphasis on the commom poor calibration of weld power sources with robots. Also have some one check the input popwer and the out put OCV

txtReplySubject:
RE: Lincoln 355i Power Source Spray Issues


txtReplyBody:
Thanks for the quick response Ed. Lincoln couldn't give me a straight answer and I have suspected the power source & wire feeder have not been scaled into the robot properly. This is such a painfull process to do! Why do the robot manufactures make this task so difficult?It should be something that is very easy.


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I would simply get from the weld distributor the cost of your consumables including weld wire, gases contact tip and nozzles, etc, Lets say its $20,000 and if I had a 100 workers thats 200,000 man hrs or an additional $10 /hr on top of the over head. I hope you have my management book as simpifying weld costs is well covered.


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No, I don't have the book that you are talking about. I have the GMAW & FCAW Parameter Book and the VHS tape on MIG made simple. We have a few robots, fixed automation and manual GMAW cells at my plant. I don't know if I really need to purchase two different packages because there will be duplicate material such as the DVD's? Please advise on packages or books I should have to conduct training for Robot Tech's, manual GMAW welders and Engineer/Management training (understanding).


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I have split the process control training programs into the unique requirements of welding thin steels ........4 mm and the other program for welding thicker steels. As you have bought the other materials I can sell you both CDs for the price of one package 295. Call me at 828 658 3574 if you have questions. Seand an e-mail to oder and mention this. Ed


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After going through each of the 8 welding program I discovered that there were numerous contact tip to work distance variation. In range of 1/2" to 7/8". I changed all to 1/2" using fixed pointer in place of a contact tip. I measured the current and voltage and they all seemed to be fairly close. The welds are much better, but I'm still getting spatter at the begining of all the welds, usually the first 3/4" of the 2" weld. The arc apears to stablize after the base metal is heated up. Do you have any suggestions to reduce this spatter?


txtReplySubject:
Is the Delta welder has to be made after 2004 or 2005?


txtReplyBody:
apart from the filler metal requirements treat it as you would any steel compnent, short circuit, pulsed or spray use moderate parameters. Ed


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Bob The 3 common gas shielded flux cored wires are the E70T-1 E70T-2 and the E70T-5.
The most common is the T-1,it has the best weldabiity. Can be used for single / multi flat / horizontal passes. Use on clean steels with low to moderate mill scale. Will produce superior quality and penetration than the E71T-1 wires.

The 70T-2 use when mill sace or suface contaminates are excessive. Limit to single pass welds.

The E70T-5 consider when maximum impact properties for single / multi pass welds. Also used when welding high sulfur steels.


txtReplyBody:
TRY 60 ARGON 40 HELIUM (READJUST VOLTAGE)INSTEAD OFTHE ARGON HYD AND THEN GET BACK TO ME. ED

txtReplySubject:
RE: Black scale on Automatic Mig weld (St/Steel 316L)


txtReplyBody:
You qualify the weld with a macro view of the internal weld fusion and for production you could at the start of each shift have the robot produce a fillet weld on two flat parts of the same thickness and do a bend test in the vice.

txtReplySubject:
RE: Welding Stainless Steel Fusion vs Penetration and developing a quality standard


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Only god and a few other individuals on his planet will daily attain 0%. I have always believed that one or two parts per shift is in the optimum league. 
By the way O % is attainable if all the variables are taken care of, the correct equipment and process choices are made and everyone involved has recieved the necessry training. This is not the way most weld shops want to go. Ed


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The only thing i recommend is google the name


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There are many reasons for interpass temp, prevent hydrogen cracking, hardness concerns, excess stresses and grain growth control. The codes frequently ignore weld practices which can have a negative influence on either the welds and the paraent metal. Because a code does not stipulate interpass requirements does not maean the weld and parts wont benefit from interpass requirements. Good weld practices in this situation for the contracter would be to stipulate an interpass of 350F.

txtReplySubject:
RE: FCAW S NR311ni max interpass temp. 5/64 & 3/32


txtReplyBody:
By the way I should also have added that your concerns about interpass temp are correct, however my first concerns for your project would be, 
[1] the choice of the poorly suited self shieded flux cored wires,
[2] the welders understanding of the process, consumables and the applications requirements,
[3] the obvious lack of process expertise with the project managers and engineers involved with this project. Good Luck Ed.


txtReplyBody:
mig weld thin metal of auto parts application with Motoman robots and panastar AEII500(panasonic).

txtReplySubject:
mig weld thin metal of auto parts application with


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typical pulsed WF with 035 wire is 8 to 9 m/min for 2 to 4 mm thickness With the 045 wire typicaly pulse would be approx  7 to 8


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you need to inform me what the start data is and which wire size are we talking about also the gas mix


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with 475ipm, 0.80trim, it seems that the 475ipm is too high??

txtReplySubject:
also, could not understand they use the arc start instruction


txtReplyBody:
remember without calibration you dont know if it is that number.


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Adam as you are using a push pull gun I rule out wire feed issues. The fact that you are using very low pulsed parameters and a 50 foot cable would tell me you dont have enough voltage and current available at the low pulsed settings you are using. This would cause the arc to wonder or occasionally flare. I have said many times at this site that befoire opurchasing pulsed equipment check it out, especially the low end and high end welding range. The bottom Line, this is Lincoln's problem not yours send the power source back. The Miller 350P appears to have a good pulsed low end give it a try. Ed


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In most of the good quality laser cuts I have seen, cut scale is not evident. If scale is there and the laser gas used is oxy or nitrogen then you have a scale that will contaminate (porosity formation) the weld. If your after weld leak tests indicate no issues then its likely the scale is not an  issue. Go back to the laser and check into the reasons you are getting scale and see if yoou can find the laser or gas  solutions to reduce that scale. Ed


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Typically with armor plate the weld is not there to match the armor properties. Normally for ductility a 70S-X wire is used and a simple 10 - 20% CO2 mix. As I welded 270 tensile armor plate with the E70S-X sucessfully, see Eds Projects, I cannot understand the logic of the 307 which provides slightly higher tensile and yield strength. I think someone has bought into a little electrode sales spiel. Ed


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I will not go into details as to why this filler metal and gas combination was selected. Having worked that project, I can tell you that both ER100S-1 and ER80S-D2 using a gas combination and parameters proposed by Mr. Craig will work.
I definitely recommend Spray transfer for all flat and horizontal positioned joints and short circuit for vertical up or a flux core equivalent to ER780S-D2 or ER100S0-1. I would also recommend the use of a DeGaussing unit. This material has been used to build safes also.
If you are definitely stuck using the ER307 with the proprietary gas blend, then definetly position and weld with spray. Stay away from pulse spray.


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Continuing my research concerning this application I found a study performed in Australia 1996 that found the use of a fully austenitic stainless steel consumable less prone to hydrogen induced cracking in the hardened HAZ areas when welding armor plated materials. They used an AWS A5.9 ER310 electrode with 98/2 Ar/O2 shielding gas. They also used an AWS A5.18-79 ER70-S6 with 75/25 Ar/CO2 that would not produce cracking only if they preheated the armor plate to a certain temperature prior to welding. The stainless steel electrode needed no preheating of the armor plate prior to welding and produced no cracking. After reading this article I concluded that my customer’s idea of using a stainless steel electrode could be to reduce the likelihood of hydrogen induced cracking in the hardened HAZ areas. I would appreciate your comments on this finding.


txtReplyBody:
Remember the MIG process with any wire discussed is a "low hyd process" and as long as you use commom practices to ensure moisture is not part of the application then there should be no concern for hydrogen. Of course if you want to, you can use austenitic wires for steel,is that slight increase in strength important? If someone believes that stainless wires must be todays choice for armor plate, then all the 70S-X E70XX welds that have been used on the majority of global armor plate steel welds in the last 50 years, must have been too weak.


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Point taken! This same robotic cell welds carbon steel products as well.  They use Lincoln L56 .035 wire with 90/10 Ar/Co2 gas. Would you suggest they try this wire and gas on the armor plate? If so then there would be no need for a change over, as long as their customer would allow this change!


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YES. THE LIMITATION LIES IN THE weld PROCESS EXPERTSE OF THE PERSON WHO DEVELOPS THE WELD PROCEDURES. ED


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Its more cost effective if the parts are thicker than 3/16 to use 0.045 wires, other wise the set up you have is fine. Ed


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Ron,
If yours is a question relating to AWS D1.1 let me shed some light:
If GMAW-S stands for Gas Metal Arc Welding - Short Circuit (as the AWS says it does) than no, according to AWS D1.1 it is not a prequalified process.
"AWS D1.1-2004
3.2 Welding Processes
3.2.1 Prequalified Processes. SMAW, SAW, GMAW
(except GMAW-S), and FCAW WPSs which conform to
all of the provisions of Section 3 shall be deemed as prequalified and are therefore approved for use without performing WPS qualification tests for the process. For WPS prequalification, conformance with all of the applicable provisions of Section 3 shall be required (see 3.1).

As for your question regarding FCAW...
That requires a long answer which can best be communicated in AWS D1.1.

If you'd like to shoot me an email with more specifics about FCAW I'd be happy to answer your questions.

Good Luck.

PWC


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Thanks paul I am glad someone reads that stuff and I  stilll see that SC gets a an undeserved bad rap.  ed


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Here’s another one for ya’…		
I’m a pretty good welder but using GMAW there is no way I could pass a typical 3/8 V-Groove test in 3G without running GMAW-S vertical up (0.035, 275 ipm, 18 volts).		
D1.1 states:	“3.7 General WPS Requirements	
3.7.1 Vertical-Up Welding Requirements. The progression for all passes in vertical position welding shall be upward…”		
That being the case, I don’t see how anyone could successfully complete that same Welder Qualification to a Pre-Qualified procedure using conventional Mig.  But I’ve seen plenty of pre-qualified weld procedures written for vertical up Mig.				
You are right…	D1.1 gives short circuit a bad rap.
PWC


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Reply. You have the logic. Very important to reduce WSO at tie ins. Grind and blend and don't weld over another weld if that weld or tack has a convex weld surface. Good Luck. ED


txtReplyBody:
the steel had to be heat treated before welding so welding weakens the steel in the narrow, heat affected zone. The only way to get that steel back to its origional condition is through post heat treat. Most companies leave the steel in the as welded condition.


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Think of what can negatively influence a short MIG weld length. To name a few.

[] Typically the weld start and crater are questionable, so that takes out 5 - 6 mm.
[] The plate or gage thickness, offers different heat sinks affecting a short length fast freeze weld.
[] Coatings, lubricants or mill scale effect on the weld.
[] gaps and joint dimension accuracy,
[] the weld size and weld speed will effect the weld fusion.
[] variable wire stick out and variable gun angles,
[] the communication between the robot and power source especially with the timing of the weld crater / end data.
[] the stability and performance of pulsed equipment in short weld cycle times.  

Any robot MIG weld less than 15 mm in length, is in my mind little more that a tack weld. I would like to see from designers and code bodies a minimum length which i believe should be approx 18 - 20 mm. However what ever the short length is, in determing the weld strengthg take out 
6 mm. Good question. Ed

txtReplySubject:
RE: Robot Welds and Minimum weld length size?


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Visit the MIG gas section and take a look at a mix I developed for Nickel MIG welds. This mix will provide you with arc stabilty and provide you with higher wire feed rate potential increasing your weld productivity. Ed.

txtReplySubject:
RE: Want to improve robot MIG nickel welds


txtReplyBody:
It depends on the application. 
[1] He put in a weld that is much stronger than the base metal and at this moment that weld is competing against a weaker heat affected zone. 
[2] As the part is 0.5 he likely put in a 3/8 or 1/2 flillet which means multipass or one large single pass large weld which could result in  high weld heat or elongated weaker grains in that heat affected zone. If this application was a steel work bench no problem, if this application is subject to fatique loads its a bad situation.Ed


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I sell both the Miller Access and the Thermal Arc Powermaster ranges. After using both machines in different environments, I would usually go for the Miller as it is a more adaptable machine. The RMD software (Regulated Metal Deposition)is an definite add-on if you are welding vessels or pipework. This enables you to put an root weld without the need for grinding back and which passes xrays. Thus speeding up the root, fill and cap process by about 2 thirds. If cost is an issue then Miller cannot compete with the Powermaster 320SP (Lorch) machine. As an all-round, cost effective digital pulsed, synergic mig it's second to none. Both machines are very reliable. (No warranty issues in over 2yrs.)
Fronius no longer have this market all sewn up.


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Bill, you are using an all position wire that does not provide the best results  for high current fillet welds. Change to the E70T-1 wire which has a thicker, basic slag suited to high current welds. This slag will dramatically improve the weld surface. This wire also has more deoxidizers and enable higher weld current so better weld fusion and less porosity. Ed


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If essential variables control welds and pulsed power sources from different equipment manufacturers deliver different pulsed weld parameters, the short answer is no. Again this is another good resson to keep many of your welds on conventional MIG CV weld procedures.

Good Question. Regards Ed.


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If its cast "iron" go to "WeldMold" web site they have the weld conumables and procedure data. Ed


txtReplyBody:
Mike visit the pulsed MIG section for an answer. Ed

txtReplySubject:
RE: New Pulsed Equipment  influence on alum procedures


txtReplyBody:
Hi Mr. Craig,
The cast Iron is according 93-4J (similar to SAE J434C grade D 7003) and Carbon Steel tube (2mm wall thickness) is according CEW 1 BS 6323 Parts 5 or 6. Today we use a 1.2mm alloy wire (nickel and iron) . The current parameters are: 250A and 27V with a mixed gas C25 (75% Ar & 25% CO2). The weld is good but this wire is very expensive. I would like to know if you could suggest an alternative for us. Thank you


txtReplyBody:
Believe me what ever you are paying for those electrodes, they are cheap, to what the alternative will be if that application is welded correctly. As mentioned google Weldmold and also Postle Ind for electrodes. Ed


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You need a nickel based consumable and pre heat data, visit google "Weldmold" for the electrodes and procedures. Ed


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First the tri-mix providess no MIG weld benefits in contrast to the two part argon CO2 mixes recomended at this site. Second, if you do not want to add to the carbon content of stainless you should ensure the CO2 level in any gas mix is maxed at 5%. Ed


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Mike when welding very thin gage
< 1/16 start at 100 inch/min
> 1/16 to 1/18   200 inch/min
3/16             300 inch/min
>1/4             400 inch/min
Gage voltages start at 20 voltls > 3/16 start at 24 volts. Have a good new year.


txtReplyBody:
Tom the bottom line is you are not using the best wire for the Job, instead of the all position, E71T-1 use a 1.6 mm E70T-1. This wire has a thicker superior thicker slag with more deoxidizers and this wire allows higher current. Try it you will see instant improvements. Ed


txtReplyBody:
Your voltage is too high for the wire feed rate, however the real issue is why are you using the 0.030 wire. Change to a larger wire and your problems will be eliminated. Ed

txtReplySubject:
RE: burning tips off - aluminium welding


txtReplyBody:
For single phase equipment thats beyond a toy, I like the Millermatic 252. Ed

txtReplySubject:
RE: Can you help me?  Mig welder recommendation request.


txtReplyBody:
Macro basically means you cut through a weld with a saw, and with visual or low magnification you examine the weld cross section predomintely to view the weld fusion lines and defects such as porosity or slag entrapment. If you grind and polish that weld surface and add a little acid, that surface can then be photographed showing good weld profiles. Micro would mean you highly polish that surface and with a high powered microscope examine the metallurgical structure.


txtReplyBody:
Rick the fact that most reputable global MIG equipment manufacturers make poor performing "multi-purpose" welding equipment should give you an indication of what you can anticipate from this welding equipment made in China. If you are looking for equipment performance and durability you don't shop at Walmart.


txtReplyBody:
Gerald your voltage is out of the optimum range it should be 23 to 25 volts. The wire feed range and techniques are covered for every application in my process control CD. ed


txtReplyBody:
Thats why we have 309 stainless MIG wire use at the same spray wire feed setting as you would for the same thickness steel application.


txtReplyBody:
David, if you meant "thermal spraying coatings", the answer is fully positive. Not only SS or Ni-base coatings, you may spray also ceramic ones onto mild steel or HTLA steels. No problems at all. Hope, you have gun and powders etc...


txtReplyBody:
Sorry dave when you stated spray my brain automatically went to MIG spray. As mentioned you can have the part coated with a stainless powder using oxy fuel or plasma thermal spray. Simply google "thermal spray" for companies who do this


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GOOD Question. If you are welding > 2 mm alum, apart from the cosmetic look, I believe pulsed on pulsed will offer you minimal real world weld benefits:
As you likely know when pulsed TIG welding products like thin alum tube bike frames the pulsed TIG process leaves a distinct cold pulsed DROP look which many find appealing. However when welding any alum part, the first criteria should be be attain consistent optimum weld fusion with minimum porosity. When welding > 3 mm alum, spray is excellent and when welding 2 to 4 mm alum I would consider pulsed. I would COMPARE MIG equipment (push pull gun), 0.046 wires, with conventional pulsed MIG equipment from ESAB - OTC and Miller.


txtReplyBody:
With 75/25 CO2 and 035 wire in the parameter range you provide its a mix of spray and small globules. ED

txtReplySubject:
RE: High Current Transfer mode with .035 and 75/25


txtReplyBody:
Aside from stability or performance, can pure "spray transfer" be achieved ?


txtReplyBody:
Josh all the data you need to elimiate contact tip burn backs, equipment down time and process optimization is in the robot (automated) weld process control training program in the training section. Ed


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Tom its not a rule you apply if you take into consideration the different wire diameters, weld transfer modes and current used. Remember these are the same companies that when providing robot guns, often provided guns with the contact tip sticking out side the nozzle for spray and pulsed applications. 
For Short Circ low amp applications < 150A, I use a WSO of 3/8 and 1/2 inch for higher SC current. Pulsed and spray I typically have set 5/8 WSO for MODERATE amps and  3/4 WSO when using over 300 A. Regards Ed


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Tony this subject is well covered in the pulsed MIG section. Ed


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Increasing the wire feed run in. is beneficial to reduce burn backs with aluminium wire and with automated high speed steel applications using lower wire feed rates at the weld starts also reduces the opportunity for burn backs. Ed


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Mark, contamination is contamination. Water cutting may not leave oxidized parts but it can leave contminated residue in the particles created in the water operation. When you don't add TIG filler weld, you greatly increase the opportunity for porosity. To prove your point, do a few scrap cuts that are ground clean and compare them with the as is water cut parts. Ed...


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The answer to this is in the pulsed MIG section, "OTC" pulsed equipment.


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Rowdy lets put one thing to rest. I have been MIG welding now for just about 50 years and never once had to use an 0.023 wire. I would recommend the single phase Miller 252 with an 0.035 wire and spend a few bucks on my manaul MIG process control program so the weld personnel know how to get the most out of this $2500 MIG package which includes a built in wire feed control and gun. Good luck Ed


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Jeff you did not say how thick the billet is or what type of weld equipment you have raditional CV or pulsed. ED


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Remembber if you know how to set a mig MACHINE spatter is not an issue, so it's up to you, spend $200O extra and get a good pulsed weld or spend $200 on MIG training resources and get a good weld. If you are welding gage alum get the pulsed. Ed


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At this weld current I assume your lb/hr delivered is 3 to 3.5 lb/hr then. A small 3/16 butt or fillet would be around 20 inch/min. Again all this data is in my self teaching process control programs..


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STT and RMD provide their weld benefits for the pipe root and are not necessary for other carbon steel applications. However as you are getting a multi purppose unit you can pipe root with TIG. As for the best "multipurpose MIG unit, Miller Esab or Lincoln, they are mostly all similer in performance, ensure you have a minimum of 250 amps for the mig CV mode. My preference is to have a 252 Delta Weld and a seperate low cost TIG unit.


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Thank you that was my opinion, I needed a qualified answer.
                                                                                                     Respectfully 
                                                                                                                David Dzik


On Tue, Feb 10, 2009 at 1:43 PM, Ed Craig <ecraig@weldreality.com> wrote:

 A 1000 of an inch of fused weld provides a 100% fusion, the question is do you believe you can produce consistent weld fusion by using a weld procedure that will provide such a small amount of weld fusion. Weld procedures need to be established with good weld fusion to compensate for the many variables that can impact a weld. Ed


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RE: Wanted. Weld eng for Edmonton Alberta


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if they feel the need to usa an austenitic wire they should be using 309 or 312.


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Excellent reply.  I've done thousands of etch tests on Mig welds that show little side-wall fusion.  I'm almost always asked, "Who cares how much as long as it is there?"  Your reply has been my reply. If a PQR is completed and sidewall fusion is minimal then in production you can expect it to not exist at some locations.  PWC


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first could you explain why your company is  using an 030 WIRE and the unecessary 3 part gas mix when the best results will come from an 0.035 wire and argon co2 mix


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This procedure is the copy from our colleage, our management does not want change it, I am not quite sure why they chose this procedure. I would rather use GTAW to apply on this weld instead of GMAW. By the way , WFS is 500 ipm , I have spelling mistake using "wps".


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Is that to say that a joint with a thousandth of an inch of fusion will be equal in strength to the same joint with fifty thousandths of an inch fusion?  I understand what you are saying about fusion being fusion, and you need a buffer for production variables, but isn't joint integrity involved in the level of fusion as well?


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fusion is fusion, from a mechanical strength point of view the fusion depth is irrelevant.


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Jake my first evaluation would be with the plasma process which I like to call modified TIG and if i used TIG equipment I would ensure it provided adjustable square wave unit which will , compare straight argon with argon 50 helium as the helium mix if you wish should also provide cleaner welds. ED


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Now I dont know if hens teeth means they are in short supply or rare. All delta welds have a similar slope out and provide excellent performance some delta welds have built in interface for automated welds and with out checking I believe thats the capability of the 452 (I am in Austrailia at this time for my sons wedding). As for Fegie as United are likely to win more tournaments this year than any other global team, at his age he would be crazy not to retire. Good Day Mate...


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east coast Westwood Intergrators North Carolina talk to Terry Baxter West coast Wolf Robotics Fort Collins CO these companies both sell ABB robots and their level of expertise is exceptional.


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Are there any disadvantages to OTC and/or Panasonic?...

Apparently all three (OTC/Panasonic/ABB) are interested...and providing proposals

I like to deal with welders not salesman so until we review their pitch I am uninformed...

We are looking at welding gauge steel thru 1/4" as well as T4 aluminum


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You will see the best multipass results with 
50% Ar - 50% helium.


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YOU CAN WELD IT WITH STICK, MIG, TIG,PLASMA, FLUX CORED, SAW LASER, ELECTRON BEAM ETC. The bottom line is a poor question always ends up with a poor or wide range answer. If you google this material you instantly would be aware that its a basic material easy to weld. So the bottom line would be what do you want to attain, high deposition rates, all position welds, are you welding thick plate, thin gage. Ed

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RE: what is the welding process for welding A500 pipe?


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I would go TIG root and E71T-1 flux cored fill.Ed


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What would be your suggestions for automated pulse welding 18 ga alumized steel a corner type weld as far as shield gas and wire type (low silcone)? 

Use an 0.045 70S-3 WIRE WITH ARGON 8-15% CO2


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Thank you very much your info is always very helpful.


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As youe using high dep rocesses you may not be interested in pulsed MIG. Fronius equipment works very well with these alloys


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My preference wouldh not be any of the ones you listed. Your TIG clad application benefits from the pulsed process and for that, I prefere the TIG pulsed arc characteristics availble from Fronius equipment..

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RE: Best quipment for TIG clad welding ID pipe?


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Question: The solid wire filler metals (a nickle alloy and a low alloy steel) for GTAW manual and machine welding are stored in a wire "cage" inside our welding area inside our temperature control but not humidity cotrolled manufacturing facility. Other than making sure these items are covered to prevent surface moisture or dust contamination is there any other precautions that you would recommend? 
Answer: Its important to know the age of a wire and how long its been on the weld shop floor. been out Stick a tag on each box and show the date purchased. When you open the MIG wire box tag the reel. To reduce humidty you could purchase a low cost dee-humifier from Lowes < $200. With your TIG operations watch out for wire surface powder issues which can contaminate the tungsten and block the copper wire feed tubes. This powder comes from the wire coating and the amount will differ from different wire manufacturers


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The same way as you measure jules for spray transfer.(data provided in the cost and metric conversion  section ofthis site) Remember its the average pulsed current that is indicated on the pulsed power source amp meter.


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You indicate two products please be specific or clarify with the weld data for each product


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this is precisely the calculation I used and was told by a client that this was an unacceptable method to determine heat input for pulse.


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It would be great if you could set up a mechanized carriage and automate these welds to inprove the weld travel rates and minimize the start stops. For manual welding I would use a basic 70t-1 wire, size 0.062 with CO2 and weld in the 350 - 400 amp range with approx 30 volts.


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A PRIME PROBLEM WILL BE WITH MIG SHORT CICIRCUIT ROOT AT 5 – 7 O’CLOCK, POSSIBLE SUCK BACK AND PIECES OF WIRE STICKING  INSIDE THE PIPE, Ed 

 


--------------------------------------------------------------------------------

From: Randy Simko [mailto:randysimko@yahoo.com] 
Sent: Friday, May 01, 2009 11:01 AM
To: ecraig@weldreality.com
Subject:


txtReplyBody:
If the 70T-1 is approved for an argon mix such as 25% CO2, it's likely an argon 20% CO2 is acceptable. The argon 20 CO2 is great for all MIG welds. Lower CO2 content than 20% will possibly increase the welds mechanical strength,decrease the ductility and provide less energy influencing fusion. You could ask the wire mfg what the weld mechanicals would be with the 80/20 gas. Ed


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I would want an AC/DC inverter that provides for the alum welds AC Balance control with another important feature, adjustable weld frequency, this weld frequency contoll will typically provide up to 200 Hz. The AC balance / weld freq control combination while much more costly than AC TIG equipment with a balance control, provides opt alum welds with the greatest weld control and at the fastest weld rates. Google TIG Inverters and take a look at whats available.


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Mark if you want more data call me at 828 658 3574 Ed


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To attain this 3/8 weld around 55-65 IPM, give consideration to a 700 / 1000 amp advanced square wave TIG power source using a 3/32 or 1/8 metal cored wire and submerged arc flux. When you use this strange combination for a saw weld, with approx 70% EN, combined with approx 15 Hz and a 600 - 800 amp range, you will achieve a single wire SAW weld with 3/32 or 1/8 metal cored that typically deliver the equiv of the much more costly Twin Wire MIG process. Ed

txtReplySubject:
TIG equipment may provide the greatest deposition


txtReplyBody:
This question makes me weep for this reason. This whole web site, (for those that read more than 2 paragraphs), sends a message to the weld industry that weld settings are not about individual weld experience or weld sounds. MIG welding is about deciding on the weld mode of transfer, selecting the optimum wire size and selecting one of three argon CO2 gas mixes. You then set the correct wire feed and voltage. So instead of looking for that manual which will tell you nothing go to the weld training / education resources at this site and start there. By the way if I am wrong in my reaction to your question, I apologize. If you want more give me a call at 828 658 3574

txtReplySubject:
RE: Manul for a CK Systematics mig 140 sms/ fw 111


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Weep not!  There are many, many, many of us that have read well beyond Pg. 1 Par. 2  We appriciate the information.
PWC


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Thanks Paul, when it comes to welding I often feel like an island. Ed


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I have achieved 55 to 85 IPM and the methods are described in the robot weld process control self teaching / training resources, Ed


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why not go to this site index, click on self shielded flux cored wires and find out why no weld professional would use these wires. Ed


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Rowdy I will let you do the product comparison at the Miller and Lincoln site, with this equipment simply look at the total package price and the current out put at 60% duty cycle. You can produce excellent SC MIG welds on the 16 GAGE, Again my preference for a TIG power source would be Miller and for gage steel welds I would get a 150 amp unit. Ed


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Good question? I will put this one in the hands of our loyal TIG welders. Can some of you weld for 30 seconds on a piece of steel or stainless >1/4 scrap, set your TIG welds at 250 amps and let me know the length of TIG wire used, also the size of the wire used, I would appreciate it. Regards Ed


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I dont suppose you could recommend a replacement wire Ed,I would love to use gas shielded flux core wire but our site is too windy..


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Seems like a simple math problem that could be worked out quickly by anyone other than I.  I top-out at about 8th Grade.  :-o  Something about Area of a triangle/Area of a circle...  Good Luck, PWC


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Wind is something a piece of wood or carboard could stop. In ship yards and on pipe lines they find ways to stop the drafts and use an E71T-1 gas shielded flux cored wire. Ed


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Karl I am exited to tell you about a new process that is superior to traditional TIG, Pulsed MIG and flux cored. Go to my home page for info. Regards Ed


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Using aged wire we think caused pinholes and porosity.  Could you tell me what type of degradation that was most likely occurring to cause this type of defect?


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If the wire looks clean (run wire through tissue to reveal the surface condition ) and check to see if the wire cast and helix is within the AWS spec for a reel / drum. If you feel that the wire manufacturer can be trusted to ensure that the chemistry is always what its supposed to be then you check the weldability. Run the wire in the spray mode check the minimum voltage and in the spray mode run a weld for a minute or two listening to the arc sound and checking for arc length variation which if occur typically mean a chemistry inbalance. With weld wire a small part of weld cost (<20%)(your company would be better served to focus on process knowlege / best practices.


txtReplyBody:
Phil, In addition to the tests Ed describes, evaluate the wire in the package you intend to use…  Helix on a 33# spool can be considerably different than on a 500# drum.  I had a company brag that their wire helix resembled more of a sine-wave than a circle.  They were right, and that sine-wave was the reason the wire constantly changed directions as it exited the contact tip.  Welding a 7 inch open root, it was almost impossible to not get IF at some locations and there is no way a robot would have been able to track with it.  Try and get 3-4 samples from different “manufactured on” dates.  I had 4 drums from the same China supplier.  2 worked flawlessly (Good helix, clean, smooth/consistent operation), 2 were drums from hell (Sine-wave helix, snarling, inconsistent arc).  I’ve probably tested a Mfg a month over the last year.  Most from China.  Nothing beats an L-56, but it is too easy for a “bean counter” to run the numbers and ask “How much trouble can we put up with?”  PWC


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BEST PROCESS WITH LEAST FEFECTS AND MOST SIMPLE PROCESS TO LEARN FOR ALL VERT UP  AND OVER HEAD WELDS IS THE NEW TIP TIG PROCESS. INFO ON MY HOME PAGE. Flux cored is not difficult if you know how to optimize the settings, that info is in my training resources


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Glad you like the clock method. TIP TIG typically requires a couple of settings for most applications. However  I will have a simple rule of thumb for all manual and automateds settings up within a a couple of months. Regards Ed.


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I would assume that the Titanium picked up carbon from the grinding wheel or contamination from the water. This should be a surface condition that can be removed. Check that the grinding wheel used is the type that 
should be used with titanium and don’t use that wheel or disc on any other metals. My titanium section has info on this subject Regards Ed  

 


--------------------------------------------------------------------------------

From: Esteban Acosta [mailto:exodus125@hotmail.com] 
Sent: Thursday, July 02, 2009 12:05 AM
To: ecraig@weldreality.com
Subject: question about carbon contamination


txtReplyBody:
George If you want the best method to weld these pipes and ensure you recieve defect free welds at faster weld travel rates than you would attain, visit the TIP TIG section of this site and scroll down to P91 info. Ed


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both machines are similar in peformance, my pref ESAB, ED


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Listen to Ed and do it right in the first place. Use 0.35 wire, Ar15%CO2, 29.5v, 425ipm WFS for proper spray on this application.


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Forget about changing consumables and change position to the 1FR (Flat, rotated) position.


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We are limited to the 2F position and we cannot automate the process.


txtReplyBody:
5/16 horizontal fillets are areadily made with 045 mig wire at 450 ipm (1-2 o'clock) 28-30 volts and argon 10CO2, the steels should be ground or sand blasted. If the welders dont have the MIG skills use a 1/16 70t-1 wire with straight CO2 at 300 ipm (11-12 o'clock) 30 volts. Ed


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If you want a real world weld solution be more descriptive of your weld issue, the weld and end data parameters, the wire size, weld type and size and is the problem occuring in the weld or in the weld end data?


txtReplyBody:
Thanks for the replies.  Those are very helpful.

Phil


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Guys like me spend a lifetime writing books for guys like you. I wish someone had told me at the start of my career that few people want to buy a weld process control book or resource that would further their career. Data 250 - 300 ipm 24-26 v push. Books at www.weldreality,com "Eds Training Resources". Ed


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By the way the power supply is called Fronius


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It's not even a competion, for automated welds Fronius is easiliy the first choice. Recently while in the the UK assisting a client on sub sea valve cladding I had the latest Miller and Fronius TIG power sources welding side by side on complex inconel bore cladding applications. When you get these units welding next to each other using the sme parameters the superiority of the Fronius weld performance power source stands out. Ed


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Bill as its a steering column and its a nice component to hold onto, I suggest you use TIG welding for this weld and consider a 309 wire. Ed

txtReplySubject:
RE: Hot Rod Problem - How to weld stainless to mild


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I assume its MIG so it will be around 150 ipm


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Aluminum is a key in the selection of TIG equipment. If you want to provide optimum alum welds, you need to look at tig equipm with balance wave controls. If alum is secondary then any square wave AC/DC equipment is fine. Frankly for manual welding, MILLER, LINCOLN AND ESAB in the amp range you are looking at are so similar in performance they could be triplets. Ed


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If interested I will tell you the story on this one....
904L to CS stinks....904L-904L FCAW not bad once welders learn how to manage travel, WFS, volts to maintain low heat input...Get the right brand of FCAW.


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My 2 cents... Change to a U-groove and grind/file the tacks.  PWC


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Friction is typically done on butt welds in the flat position and why on earth would anyone with an ounce of common sense look to friction for this application?


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Grind the tacks very carefully and leave a very thin tack a few thousands of an inch, that way you can prevent the contamination and maintain the keyhole, pulsed TIG would also benefit, Ed


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Would you recommend a fast or slow pulse action?


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There is someone coming to the Sept TIP TIG workshop from Australia. Send me an email at ecraig@weldreality.com with your full contact and I will provide him with your info...Ed


txtReplyBody:
wish you guys and I wish that many of your generation had the energy and time to complete a sentance. I take it you are referring to the MIG weld process, and if you are, perhaps you could take a moment of your valuable time to look at the MIG gas section in which I have spent 40 years of experience and hundreds of hours placing my views as to why argon does not work with MIG. Regards Ed..


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This one is easy, look at TIP TIG it will easy achive your weld reaquirements. If you need other options be a little more spefic to your process details and parameters uses. Regards Ed.

txtReplySubject:
RE: Tips for getting full penetration welds.


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Fronius would be my first choice however Fronius cannot match TIP TIG WHEN TIP TIG is attached at any low cost TIG power source. Ed,


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Frank if you want to eliminate and I mean eliminate weld rework and use one process for the the duplex root and fill passes, there is only one process that will do that, Visit the TIP TIG section at this site. The worlds biggest manufacturer of duplex vessels for breweries and food processing uses will only use TIP TIP


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Scott as cables provide the current to the two terminals it should be possible with the 225 to change the polarity, however why  bother with the self shielded wire, the welds are not going to please you especially when you could have used a superior gas shielded flux cored wire with REP. I know you are out doors, however a piece of wood or cardboard will provide wind protection. ED


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BJ YOU HAVE VISITED MY SITE, LOOK TO THE LEFT FRAME AND CLICK ON "EDS TRAINING MATERIALS" AND YOU WILL FIND THE RESOURCES TO BECOME A TRUE WELD PROFESSIONAL. ED


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Andy ABOUT 2 INCHES TO THE LEFT OF THIS WORD, IT STATES "EDS WELDING AND TRAINING MATERIALS" ed


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The answer is yes, however who you get the flux cored wire from is critical. I would prefer for this application a "Kobelco wire" which runs very well with CO2. Dont forget that the best all position weld process for code qulaity pipe welds is TIP TIG. Ed


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The best process for this application is TIP TIG, AND TYPICALLY WE WOULD USE AN ALUM BRONZE WIRE. ED

txtReplySubject:
RE: RE: TIG welding Brass to CopperNickle


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Henry lots of TIP TIG features benefits in the TIP TIG SECTION. The bottom line the cold wire system (typically automated) is "very senitive to wire feed and many weld issues are commom. The cold wire feed rates are low. The TIP TIG hot wire sytem is unique in that the weld pool is agitated which changes the weld surface tension and the weld solidification. The logical thing to do is show the guy the videos and ask if his cold wire unit can do the same. Call me at 828 658 3574, ed

txtReplySubject:
RE: Difference between TIP TIG and the CK cold wire system


txtReplyBody:
FOR DECADES THE WELD INDUSTRY HAS FOOLISHY FOCUSSED ON WELD CONSUMABLES TO SAVE WELD COSTS WHEN CONSUMABLES ACCOUNT FOR LESS THAN 20% OF THE COST OF A WELD. TELL YOUR OWNER FROM ME IF HE WANTS TO SAVE MONEY FIRST LOOK AT WELD DEPOSIOTION RATES, THEN LOOK AT THE ARC ON TIMES, THEN TAKE A LOOK AT MATERIAL HANDLING,THEN LOOK AT ALL THE UNNECESSARY WELD GRINDING AND CLEANING, THEN LOOK AT THE COST OF WELD REWORKS. YES THERE ARE FLUX CORED WIRES THAT RUN WELL WITH CO2, HOWEVER LOOK AT THE THE SPATTER AND FUMES GENERTATED. BY THE WAY IF YOUR OWNER  TOOK OWNERSHIP OF HIS DOMAIN AND READ MY MANAGEMENT BOOK ON WELDING HE WOULD ASK THE RIGHT QUESTIONS AND FOCUS ON THE REAL METHODS TO REDUCE WELD COSTS. OF COURSE IF YOU WANT TO KEEP YOU JOB KEEP QUITE. ED


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They should not be allowed near aluminum, you are correct. Ed

txtReplySubject:
RE: Blasting 6061 angle to remove clearcoating on the surface


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Mike I developed a unique flux cored process control program that explains all the weld settings and techniques neccessary for all position ceramic backed welds. Its in the Ed's Weld Training Materials. Ed


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You are wasting money with your 3 part gas mix and the salesman is a salesman. I spent many hours writing the MIG gas section of this site, the gas data you need is there.


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Tim,  Wake Up!  Welding sales folks dole out that kind of crap every day, and welding decision makers, like us, need to beat it down the minute it is uttered.  Your purchasing group is going to hear this guys BS and not think twice about a switch.  Then they are going to come to you when they don’t see a savings.  Take control of your weld process and call these guys out the minute they open their mouths.  On the other hand… why was the decision made to go with a 3-part mix in the first place?  ...more than likely a salesman selling “pixie dust”.  PWC


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Some weld logic. Try a sample weld first. With MIG try a regular E70S-3 wire with argon 20 CO2 if welding in the flat or horizotal position. If all postion welds, simply select one wire, use an 0.045 E71T-1 wire with the same gas. ( SMAW use 7018) At first dont use pre-heat, avoid welding near existing welds as they will have super hard HAZ. If your welds or repair welds creates cracks in the surrounding weld consider installing a new piece of regular carbon steel plate with the welds on the plate away from existing welds. Try a small weld area and at the weld completion check the weld and base metal with Dye Pen. If  cracking in the base, try 300F preheat. If cracking in the weld try a 312 stainless wire. Good luck

txtReplySubject:
RE: Military Steel-welding hardened steel w/mig


txtReplySubject:
RE: mig welding inside corners in ss tanks


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WE DONT MAKE WELD CONSUMABLE CHOICES AS THERE ARE LIABILITY CONSEQUECES, ED


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all optimum data available in Ed;s Process Control Train Resources at this site.


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035 wire and high end SC with arc focus on the thicker part

txtReplySubject:
RE: Advice on welding 6mm solid round bar to 1mm sheet mild steel


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Rather than pay a premium for Flamex simply compare it with propane and I know you wont see anything that can be measured. Ed


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Ken,  I would suspect that your weld penetration profile is showing “finger penetration”.  Not sure if that is a real term or not, but a real deep area of penetration at the weld root (I wish I could draw it out).  The profile is much deeper (at this location) than it is wide.  This will cause this area to open up during solidification.  Grab your copy of AWS D1.1 and check out the Commentary section at C3.7.2  Typically, a reduction in current (WFS) should remedy it.  Yours is a weird shielding gas mixture.  Not sure why you would go with so much Oxy, but I don’t know your whole story.  If you can, increase the Co2 content perhaps that will change your weld profile.  Good Luck!  PWC

txtReplySubject:
RE: Linear porosity in root & heat affected zone


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If the jobs require high weld clad or hard facing quality and you know TIG or stick welding is likely to be used. then be aware that TIP TIG will provide that quality at about 20 - 30% of the costs that other weld shops will bid.

SYo

txtReplySubject:
RE: Starting new biz, and trying to start a Niche for myself


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I cannot believe you were using a SALES INDUCED 3 part gas mix with 4 percent oxy and then having a concern for weld oxidation, change to an argon 15 co2, however as your porosity is also focussed in one area direct your focus also on the parameters in that location, ed


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Joe 
[1] Look at the surface condition. Its likely Caterpiller used sand blast to remove the mill scale. When you weld on mill scale it has higher melt temp than the weld wire and creates a sluggish lumpy weld.

[2] If you want to get better weld surface quality from the Lincoln power wave, turn the pulsed mode off and weld with spray. Ed


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Ditch the tri-mix and use Argon with 2-3% CO2 for your stainless welds. Just like Ed's books say. You will be happy. Make sure the surfaces are clean and you are using good wire. The inner weld is affected by the quality of the outer weld.....


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Ed C,  
What are you comparing?  I would liken your comparison to comparing stick welding to 7018. Oxyfuel cutting to Natural Gas.  A hydraulic system to transmission fluid.   
Pulsed Mig welding (GMAW-P) refers to a transfer mode of the Mig (GMAW) process.  Metal core refers to an electrode type used in the Mig (GMAW) and Sub-Arc (SAW) processes.  I can use metal cored electrodes (E70C-x) with the Mig process in its Spray, Globular and Pulsed transfer modes.  So what is it you are comparing?  
PWC


txtReplyBody:
GMAW (MIG)using bare solid wire
      Pulsating 
      Materials thickness range from .5" to 1.75"

      Very few issues being encountered


      MCAW - (MIG) Metal Cored wire
             Spray Arc
             same wall thickness range

      Encountering severe issues with Porosity
      regardless of station, shift, or personnel

      2G - Horizontal
      Multipass
      Material is SA-516 / Gr 70


txtReplyBody:
Should be a pretty simple material to join.  No reason either welding process should be giving you problems.  I’m assuming you’ve checked shielding gas flow rate (35-45cfh).  I’m also assuming the surface condition is the same.  I kinda’ have to laugh… Folk ask me to trouble shoot their welding issues all the time, but provide almost no useful information.  What is your shielding gas mix?  What is the diameter of the pulsed solid wire?  What’s the Wire Feed Speed (WFS) and voltage (trim) used?  Same questions on the Metal cored electrode, what dia., WFS and voltage.  Why on earth do you use the pulsed process on such heavy material?  What benefits do you hope to gain from pulsed mig?  Why not simply use Spray transfer with solid wire?  What do you hope to gain from the Metal cored wire?  Questions, questions, questions…  PWC


txtReplyBody:
Sorry ... kind of doing this on the fly so to speak.Just when I get a chance to walk by the computer. The MCAW process is using .045 wire at 235 amps , 325 on the WFS , 26 volts , travel speed is 6 ipm , and a gas mix of 80/20 ( Ar/ CO2)at 35 cfh.

The GMAW pulse is using an .045 wire diameter , at 215 amps with a WFS of 280 at 23 volts. Travel speed is 6 ipm and the gas is 88/12 (Ar/ CO2) at 35 cfh.

And my apologies once again as to not being specific. These processes are primarily being used as root passes. The fill process is then a Subarc procedure.


txtReplyBody:
Hi Ed,  Lookin’ at these side-by-side I see little reason for excessive porosity off the MC.  Personally, I would ditch the MC and ditch the pulse.  I would use the solid wire in CV mode with the 88/12 (or an 85/15).  I’d run the 0.045 at 325-375  WFS, 26-27 volts and I’d bump-up the travel speed by at least an additional 10 ipm.  But that’s just me.


txtReplyBody:
Your ER70s-6 is supposed to meet the requirements of AWS A5.18 unless you and your supplier have agreed on some other requirement. That being the case, your electrode is outside the tolerance requirements of A5.18 (0.9mm = 0.91 to 0.86). I test a lot of electrodes and have not found them to be outside the tolerance. In fact they rarely very in diameter enough to come even close to the edges of their tolerance. Inconsistency with cast and helix and poor quality copper coating is the issue I see most. If this electrode is consistently inconsistent and your contact tips are equally inconsistent, you’ll never solve your welding issues. Keep in mind, the electrode and contact tip are similar to an electrical connection.  If the surface of either or both are in constant change, so will your current (resistance) be in constant change. You are going to experience arcing inside the tip which will manifest itself in burn-backs and frustration. But think of the money you’re saving.  :-0 PWC

txtReplySubject:
RE: Dirt Cheap Wire and Dirt Cheap Contact TIps


txtReplyBody:
consider welding with TIP TIG and you have a 50% reduction in weld heat, if not consider pulsed MIG


txtReplyBody:
Sorry paul not dead yet going around the country with TIP TIG and soon of to Austrailia to demo to the aussies, so its been a bit hectic, so dont forget when I am no responding jump right in there because the BS in this industry keeps getting thicker. ed


txtReplyBody:
A company like yours should move to China where they can get cheap labor to go with the cheap weld consumables. What happened to American pride in the products they produce?


txtReplyBody:
Are you out of your mind, why not scrap the parts before you weld so you can save time. Ed

txtReplySubject:
RE: Weldability of Monell 400 to Alloy 31, Nicrofer 3127 hMo


txtReplyBody:
Why be in an argument. As you are discussing two seperate subjects.Pulsed MIG is pulsed MIG an overated process for steel welds. Metal cored is a consumable with a powder in it;s core and if you use metal core with MIG spray, short circuit or pulsed you will use a little less current which at the end of the day is not going to help you with weld fusion. Ed


txtReplyBody:
Shame on Praxair for either its lies or stupidity and shame on your company for having no one who will use a little logic. The commom denominator of the weld problems you will have will be oxidation, burn through and distortion, (heat issues) yet some stupid salesman has recommended you purchase the world's hottest gas mix. For gods sake read my MIG gas section and lets get a little weld reality in this industry. Ed


txtReplyBody:
At the Systematics web site http://www.800abcweld.com/video/ you can download an owner's and service manual for the Snap On MM140 machine made by Systematics.


txtReplyBody:
The bottom line, "a complete waste of time"

txtReplySubject:
RE: Hammer peening on Austenitic Stainless Welds!


txtReplyBody:
035 wire 500 - 600 ipm > 26 volts argon 10 co2


txtReplyBody:
Its been my experience that toy welders belong in toy shops. Many of these home units bring great dissapointment with MIG however there is some potential to get good welds out of 035 gas shielded flux cored which work well with low parameters,


txtReplyBody:
i'm in ontario canada is their a time zone difference


txtReplyBody:
measure the wire feed as it exits the gun, your issue is usually caused by a wire feed rate set too low or if the wire feed is correct it could  be restricted as it exits the tip.(wire tension issues or chinease made contact tips with the bore too small, Ed

txtReplySubject:
RE: Blow Back Welding Aluminum with Spool Gun


txtReplyBody:
the books just came in i will read a bit first can i order your books individually and how


txtReplyBody:
your answers are in the MIG welding alum section of this site

txtReplySubject:
RE: Minimizing color difference post anodizing


txtReplyBody:
The bottom line If you are going to use weld equipment that provides less than 200 amps and you want quality welds consider using 0.035 gas shielded flux cored. As for the weld equipment look at what the best "package" deal is available. Ed


txtReplyBody:
will be in Perth May 24 for the week and then the following two weeks in Sydney, anyone wishing to discuss TIP TIG, or MIG and flux cored process improvements or training contact me through ecraig@weldreality.com. Regards Ed

txtReplySubject:
RE: message from Ed about Australia visit


txtReplyBody:
go to the steels section  and if you need more data simply google welding AST A 333

txtReplySubject:
RE: I need to know whether ASTM A 333 Gr,6 pipe of 31mm thick needs postweld heattreatment or not.


txtReplyBody:
as long as you can use > 330 amps and you use a 70t-1 wire in the flat position the 1/16 wire will be faster. If welding vert up the 045 wire would be the first choice, Do you know how much I cringed when you said you "asked a salesman". Ed


txtReplyBody:
use TIP TIG with 0.045 wire and attain better quality with 200 - 400% increase in deposition


txtReplyBody:
yes send me an email ecraig@weldreality.com and let me know which one you want


txtReplyBody:
its not my job to suggest a weld wire for a code weld, and as for controlling weld impacts i suggest you concentrate on controlling the weld heat and weld cleanliness. Ed


txtReplyBody:
Suppose we put 12 liters of 87 octane in a car, how fast will it go?


txtReplyBody:
we used to say in the good old days (pre 80s) that there was no such thing as a stupid question, I will not even try to answer this question. Give some serious consideration to the question and then give the same consideration to the information that was not put in the question. Ed


txtReplyBody:
I had a Drill Sgt. that once told me, "Cameron, there were no stupid questions... 'til now."   

:-0


txtReplyBody:
best lincoln power source for a robot is a "miller power source" For your welds you simplly need a 400 - 450 amp CV power source with the ability to communicate with ABB. Today its possible you may have to purchase some useless pulsed MIG equipment as this is the only equipment available with the electronics required for that communication. Ed

txtReplySubject:
RE: Best Lincoln power supply for ABB robot


txtReplyBody:
Ha, Ha, Ha...    I read this post and my first reaction was, A Miller.  Then I saw Ed's post.  Too funny.   PWC


txtReplyBody:
"best Lincoln power source for a robot is a "miller power source" Thank you I couldn't agree more. Unfortunately I'm "just" a lowly programmer/operator, and my Manufacturing superintendent and weld technician are Pro Lincoln


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The bottom line is treat the metal cored wire like a solid MIG wire except at a specific wire feed setting expect approx >10% less weld current with one or two volts less. Please keep in mind for most weldss on steels < 3/8 you are wasting money purchasing these more expensive wires, and if anyone tells you otherwise they have been influeced by a salesman. Ed


txtReplyBody:
I am still in austrailia call janet in north carolina at 828 658 3574


txtReplyBody:
the answer to your question would have been different six months ago, however any pipe shop that today is not considering TIP TIP for all pipe root and fill passes, is a pipe shop that wants to loose money

txtReplySubject:
RE: do we need STT and pulsed MIG or fcaw?


txtReplyBody:
Frank I went to Austrailia to open up a TIP TIG distributor and while there had a little flare up with some old cancer cells, so i am am having a unique long wave radio pheraphy treatment in Perth for the next few months, beats going the chemo route, so if you or my other freinds want to chat keeep the emails coming to ecraig@weldreality.com, regards Ed


txtReplyBody:
Best of luck with the treatment and get well.
Paul W Cameron
PWC


txtReplyBody:
If my math is right (and loosing the metric)...
a 0.094 in. (3/32)dia. solid electrode fed at 177 ipm will deposit 20.5 lb/hr


txtReplyBody:
the best tip would be have some pride in your welds and do not use this junk. Ed


txtReplyBody:
it means the spray weld data is typically optimum, the last place to freeze in a weld is the weld center and that solidification line typically means even distribution of the heat over the total weld length so well done, ed


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Funny side story...  While working at a railcar mfg in WV I had the equipment setup to achieve this condition.  I had so many radio calls regarding cracked welds that I had to teach a class in using die-penetrant and tell them that when they saw an indication, call me.  Radio silence.


txtReplyBody:
(http://www.weldreality.com/ASTM_A645-A973.htm)  There's a good chance you'll find the information you need at this link.  Be cautious about welding on anything that the manufacturer advises against. I'm sure this isn't an impossible task, but anyone helping you out would need far more information on the repair.


txtReplyBody:
Brian I would SLIGHTLY increase the burn back time and lower volts. Regards ed


txtReplyBody:
Cliff, This will be more of a challenge of your ability to manipulate a Mig gun than how to set a mig welder.  Consider getting yourself the Robotic and Manual Mig Workbook   (http://www.weldreality.com/ordernow.htm).
Try setting your Wire Feed Speed (WFS) between 375-425, Volts around 26-28.  Your shielding gas mix will limit your ability to obtain a spray setting, but these parameters should work for you.  Keep a consistent push angle (15 deg) and a work angle about 25-30 deg off of 90.  Focus the arc at the weld root but slightly favor the 3/4 plate (1 x wire dia). You'll end up with a slightly longer Fillet leg on the lower plate, but the weld should wash up onto the bar far enough to be acceptable and not undercut.  Personally, I have to break this up and do 1/2, then re-position and finish.  
Just my thoughts, nothin' more.  
Good Luck, PWC


txtReplyBody:
Consider doing a little homework:  
(http://www.weldreality.com/Duplex%20Home%20page.htm)  You understand your weldment better than anyone.  Dig in and do a little reading.  Then, when you have specific questions, give as much detail as you can.  In addition, consider purchasing "A Management and Engineers Guide to MIG Weld Quality, Productivity and Costs".  I consider this my "Welding Bible".
(http://www.weldreality.com/eds_training_materials.htm)


txtReplyBody:
What... Did you make a bet with someone?  What is the reason for the question?


txtReplyBody:
No, it isn't bet, but it is just a disagrement.
We use E71T-1 (rutile type) in pure CO2, and it gives spray or at least quasi-spray...
But we have to do critical job on some old equipment and we consider to use E70T-1... but we are concerned about big spattering if it gives just globular transfer and maybe some failures as the welders are not familiar with this wire...


txtReplyBody:
Sorry.  I can be cockie.  I would imagine the transfer mode you currently achieve on the 71 you'll be able to achieve on the 70 (is not smoother).  Not sure why you would change the electrode classification though.  You'll be limiting your ability to work "out-of-position".  I wouldn't think weld failures would be caused by a globular transfer.  Spatter maybe, but not failure.  If the welder is competent and the material and filler are correct, this should be no problem.


txtReplyBody:
Thanks PWC... The reason to switch to basic FCW is because we are going to weld only in flat position, it is repairing of old panels, patching them with new ones etc... even new material has mill scale and is being corroding sligtly, so we expect, basic type would cope better with impurities and dirt...


txtReplyBody:
For close to forty years I have been informing those interested that if you want spray ensure the CO2 content < 21 % CO2.


txtReplyBody:
There is no such thing as spray transfer with any flux cored wire. However at one time the less CO2 you used the smaller the weld droplet transfer and the less spatter. Now flux core wire mfgs can with certain straight CO2 wires  like a Kobelco  generate a similar transfer to a wire thats typically used with argon 25% CO2.


txtReplyBody:
Ridiculous question. Please read what is states in this section about the info required. If you cannot take the time to provide that info why should we take the time to guess the answer?


txtReplyBody:
From the three or four words you generously presented us I guess we are supposed to know all the relevant data we need to provide a weld answer. 

Some cook ware may be alum, stain, coated steel or cast. Many of the alloys will be none weldable and brazing or solder can be  used. As you can buy most of this stuff at Walmart for pennies that would be my approach.


txtReplyBody:
I once had a nice little old lady stop by and ask if I could fix her lawn chair.  I told her, "I sure can".  I headed out to Wal-Mart, purchased a new chair for about $5 and brought it to her... no charge.  I went right to "Hero" status.  To answer your question, maybe, maybe not.  It all depends.


txtReplyBody:
We tried E 70T-1... We got big spattering, so we decided to use metal cored (82%Ar+18%CO2) instead of basic cored...


txtReplyBody:
This is one of those "Salesman Initiated" changes I've seen over the years...  Company’s using a FCAW process and the Sales Dude comes in and says, "Hey, you want to save $$$ on your cleanup cost? Try this new cored wire. No slag. It's awesome!"  Now the company's changed from a FCAW process to a GMAW process.  I would suspect that the Engineer has no clue this just happened because the conversation stayed on the shop floor between the Sales Dude, the Supervisor and the Welder.  They are all moving along "Fat 'n Happy" with no clue as to the SIGNIFICANT change they just made to the welds penetration and sidewall fusion profile.  Makes me want to SCREAM!  I hope you've done your testing and are getting the weld you require.  I hope you've cut and etched a significant number of parts.  I hope the Engineer, Inspector, Supervisor, Welder and Customer are all in agreement on your change.  PWC


txtReplyBody:
this is one of those questions that has many considerations and concerns before recommendations. Bottom line is if you want me to evaluate your specific application and recommend specific manufacturing practices then a little renumeration would be required.

txtReplySubject:
RE: After Weld overlay on plate , can we do cutting as petals & crown for hemihead and then forming?


txtReplyBody:
No, there is no sales rep involved in this case... We did most of our job with E71T-1. But this repairing job is to be done only in flat position, joining new steel to old one. We wanted E70T-1 because of less risk of trapped slag, and better suitability to old and maybe somewhere dirt steel. What we wanted is to make job correctly the first time without flaws or any rework or grinding... We could expect trapped slag using E71-T1 in flat position and rejected it, we saw big spatter of E70T-1, and rejected it and ... Metal cored wire (in Ar + 18% CO2) was perfect: no trapped slag, no spattering-no grinding, good deposition rate...
The customer approved our procedure...


txtReplyBody:
Mark after consideration I think you are getting to many weld processes involved. For onboard your boat you simply need a low cost CC/CV inverter power source for TIG and SMAW repairs. To build your boat I would have a 250 low cost CV MIG unit. With this unit you can alum weld (045 wire + ten foot gun), and use an 035 flux cored wire or 035 MIG wire with argon 20 co2 to build the boat. When you look at the cost of these two items its in your budget and you get the best of both worlds


txtReplyBody:
Well after you spent thousands on you robots, and did not spend $300 on my robot weld process control training resources you now find that too run robots and attain optimum weld results it's important to understand the processes. First be aware of the optimum volts  and amps
required for that short circ or pulsed weld wire feed rate, be  aware that your robots are not likely calibrated from a weld parameter perspective, and also you should be able to look at the weld wire tip profile and arc length and know  what parameters to adjust.


txtReplyBody:
As mentioned at least 1000 times at this site any company that uses this process and consumables is a company that is not interested in producing "consistent sound weld quality" therefore i WOULD NEVER PROVIDE PROCESS CONTROL TRAINING PROGRAMS FOR A process that simply cannot produce quality welds. Regards Ed


txtReplyBody:
Ed

Thank you for the reply.  The DWG wire is only sold in .045 but the claim is that it works well at lower currents. I think it is a new family.  Of course Kobelco does sell other families where I can buy .035.   Are you advising me to simply get flux cored Stainless wire with 75/25?


txtReplyBody:
You’re talking about a process that is in use on construction sites every day. Most seismic construction uses the gas-less FCAW process. Using a gas shielded process 8 elevations up in the wind really wouldn’t cut it. Gas-less FCAW in this application is the right call. I’ve UT’ed 1000’s of these joints and found them to be acceptable. Ed’s training material would improve any welders’ knowledge of the process and therefore make better welders out of them. Personally I’d start with “Gas Metal Arc and Flux Cored Welding Parameters” (http://www.weldreality.com/ordernow.htm#GMAW). There is also information available at Lincoln’s site: (http://content.lincolnelectric.com/pdfs/products/literature/c32400.pdf). I know the whole Lincoln/Seismic welding controversy, but this is the process in use today all over the US. These references should help you out.


txtReplyBody:
it means little that the process is widely used or approved by "such reputable welding agencies as FEMA" these products have no place in oranizations that desire optimum weld quality


txtReplyBody:
if your low current is compatable with the 0.045 gas shielded FCAW wire range then go with it


txtReplyBody:
Just finished reading your article on self-shielded FCAW and Chrysler (http://www.weldreality.com/Self%20Shielded%20Flux%20Cored.htm) Classic! Couple that with the stuff I’ve read in the past about Northridge, FEMA and The Lincoln Electric Co. and I understand your response. **Side Note** Before I’d seen your Northridge article, I had the pleasure of attending a design seminar run by D. M. of Lincoln. Of course, Northridge was discussed and the first question that popped into my head was, “Well, what about the rest of the existing buildings?” I asked it. As you can imagine, not a good response.


txtReplyBody:
Craig forget about using the 030 wire. For optimum spray and commercial MIG welding without "wire feed issues" if considering MIG the minimum size should be 0.035 (1 mm) WIRE.

WITH 035 YOU WOULD REQUIRE A MINIMUM OF 190 - 200 AMPS AND THE GAS MIX MUST HAVE AT MINIMUM 80% ARGON. TO GET THE BEST WELD RESULTS FROM A POWER SOURCE THAT CANNOT SUPPLY THE > 190 AMPS THEN USE 035 - 045 GAS SHIELDED FLUX CORD WIRES WITH ARGON 25% CO2. GOOD LUCK ON YOUR NEW CAREER. ED


txtReplyBody:
First its a pity your organization  did not consider TIP TIG as pipe welding Duplex is a breeze.  I am heading out will get back to you with second reply. ed


txtReplyBody:
Kurt I have gone as far as I can go with the metallurgical discussion, If welded with TIP TIG you would not be asking these questions which are more relevant to the slower regular TIG process. Regards Ed.


txtReplyBody:
would it be too much trouble for you to visit the MIG gas section in this site and read why both you and your company are wrong

txtReplySubject:
RE: what is the benefit of using trimix to weld 4130


txtReplyBody:
(http://www.weldreality.com/MIG_welding_gases.htm)  Don't give up on this.  Read the information in the above link. Learn and move forward from here, wiser and ready to take on the next stupid decision.


txtReplyBody:
(http://www.weldreality.com/flux_cored_pipe_welding.htm)  Just 5 min. of research... just 5


txtReplyBody:
could you not pick a post graduate subject that you might actually use in the real world. Ed


txtReplyBody:
John the best wire is the 0.035 as it requires lower short circuit and spray current than an 0.045 wire. By the way with that argon 25 co2 you cannot get spray so I would change the gas to argon with 15 or 20% co2... Regards Ed


txtReplyBody:
when it comes to this specific component and difficult small round weld joints, stay with the tried, tested and approved weld procedures.. Ed


txtReplyBody:
most commom applications are found in the automotive industry, tube to tube, tube to flange


txtReplyBody:
when welding gage parts the first thing i examine is the back side of the metal as the weld heat marks will be an indication of the fusion depth and the fusion consistency. This is especially important when setting robot welds as it eliminates the opportunity for weld burn through and is a good indicator of sound weld practices.. When welding thicker components that focus goes to examing the HAZ.


txtReplyBody:
on the backside of thicker metal 3/16 and up what so i be looking for, in most cases i don't have time to remove the mill scale


txtReplyBody:
>3/16 is too thick, to test welds with the data you have established run one sided fillets and do a break bend test in vice


txtReplyBody:
The real issue is will the CO2 effect the life of the tungsten? To test reactivity of a TIG gas CREATE A TIG ARC OVER A CLEAN STEEL SURFACE. MAINTAIN THE ARC FOR A MINUTE ENSURE ADEQUATE GAS PRE PURGE - POST PURGE. IF THE TUNGSTEN IS CLEAN (NONE OXIDIZED) THE WELD GAS IS NONE REACTIVE. APART FROM THAT THE CO2 WILL NOT NEGATIVELY EFFECT THE WELD YOU WOULD REQUIRE APPROX >5% CO2 BEFORE IT WOULD NEGATIVELY IMPACT THE WELD...


txtReplyBody:
Cliff, I’m surprised how little thought goes into some of the questions that come up, both on this board, and others that I write for.  It slightly worries me about the mind set of today’s welding decision maker (although it secures my job).  Think, Think, Think!  If I don’t change wire feed speed (WFS), wire diameter and required weld size how would it be possible for a shielding gas combo to change my travel speed in a GMAW application?  Sounds like you may be the victim of a bad sales pitch (although, I would suspect it’s a good sales pitch if they get the sale).  This industry seems to have lost its ability to apply common sense.  PWC


txtReplyBody:
if i knew everything about welding i wouldn't be asking stupid questions.I was alittle frustrated at the time i post this question and if i would thought a bit more i would have never posted don't worry it won't happen again


txtReplyBody:
Although I would never recommend a change in travel speed - I do kinda see where he is coming from, i.e. the lower voltage requirements might enable you to run a shorter arc length = a smaller arc width = faster travel speed.  What people fail to realize at that point is you are decreasing your flexibility in terms of part fit-up.
  
I would disagree with the statement that changing a gas mix would never allow you to increase travel speed (with all other things remaining the same) as I would expect there to be in increase in travel when switching from a 100% CO2 to a 92-8 as you would be more efficient (less spatter), thus increasing your deposition rate = faster travel speed.


txtReplyBody:
If you change an argon < 20% co2 gas you can still attain a short arc length simply by deceasing the volts. To weld faster you have to deposit more metal and with the voltage differences between 8 and 20% CO2 the voltage differences are small typically around 1- 1.5 volts. You cannot attain high deposition with CO2 unless you want a weld spatter bath.


txtReplyBody:
Shea, Your not going to get a spray transfer like you would with a solid or cored wire and a 80+ Ar mix.  You can check you wire feed speed and voltage to insure they are in the ball park. Pull the trigger for 6 seconds (exactly). Measure how much wire comes out.  Multiply that by 10... That's your wire feed speed.  Also, attach a volt meter to the + & - studs. You can read the voltage by striking an arc and make the needed adjustments.


txtReplyBody:
epending on the thickness weldded the parameter range is welding vert up you need wire feed at 200 to 400 ipm 100 to 175 amps 23 to 27 volts

flat and horizontal  wf 200 to 700 ipm 100 - 250 amps 23 to 31 volts


txtReplyBody:
Its simple, this is a con job, its a con job today as it was a con job two decades ago, Info avaialbe in the gas section of this site.


txtReplyBody:
thanks John glad to see their are live ones still out there. Regards Ed


txtReplyBody:
I think the inpregnation terminoly does not belong in a weld shop, however it does belong  in a hospital. Typically on many hard facing applications the weld consumables will provide a weld with small bits of tungsten carbide hopefully distributed throuhout the weld, Tungsten provides tremendous wesr resistance


txtReplyBody:
JUSTIN IT'S BENEFICIAL IF YOU DEAL WITH ONE STEEL AT A TIME AND I HAVE PUT ALL THE DATA AVAO;ABLE TO ME IN THE STEEL SECTION OF THIS SITE. REGARDS ED


txtReplyBody:
i have not heard anything bad about them. I like Aveseta from Europe, Kobelco Korea, and ESAB'S alloy rods


txtReplyBody:
Never hurts to start by researching what the manufacturer of the material suggests:
  Weldments of HY-80 are noted for good ductility, notch toughness and strength. It is best welded using the metal-arc process with low hydrogen electrodes of Type E-10018 or E-11018. Use approved weld procedures so as to not apply too much heat input per inch of weld bead, which would otherwise cause degradation of notch toughness. Electrodes should be warmed before use to drive off any moisture to avoid hydrogen pick-up in the weld. Preheating is not required, except for very heavy section thickness welds or heavily constrained welds. Post-heating is not required but a stress relief anneal, after welding of sections of 1-1/2" thick or greater, is desirable. However the alloy may be used in the as-welded condition.
http://www.suppliersonline.com/propertypages/HY80.asp#General


txtReplyBody:
I SUSPECT THEY ARE RIGHTLY CONCERNED ABOUT TRAPPED SLAG AND POROSITY BOTH TOO COMMON WITH THE FLUX CORED PROCESS


txtReplyBody:
You answered my question as well. Was afraid to post for fear of the simplicity of the question.


txtReplyBody:
yes if you understand the process, purchase the right weld equipment and apply weld process control logic


txtReplyBody:
if you dont know what the alloy is and there are no visable welds, its a guessing game. Try that 4043 but i would do it with TIG and and make a weld about 12 mm in length to see what happens.


txtReplyBody:
Kevin its a very good wire and if you scroll down two inches and look at the book with the red cover it would make you an expert on the flux cored process, Regards Ed


txtReplyBody:
its unnecessary to purchase a new MIG power source with "slope and inductance controls" as a good MIG power source like the Miller Delta weld will have an internal optimum slope out put with the right amount of inductance. Avoid inverters and multipurpose MIG equipment and I prefer Miller and ESAB conventional CV equip in the 350 - 450 amp range.


txtReplyBody:
Thats like asking how long is a piece of string? Do you realize all the information you did not include in your question. Ed

txtReplySubject:
RE: welding of 316l stainless steel to EHS Carbon Steel (S690 QL)


txtReplyBody:
are we discussing a full or partial penetration weld, if so what is the proposed gap and weld edge profile?

txtReplySubject:
RE: flux cored arc welding of austenitic stainless steel


txtReplyBody:
For decades companies have been trying to break into the USA market with their weld consumables and its a somple fact of life that the major weld wire manufactures (and you know who they are) will do everything possible to ensure they maintain there monopoly position. So come in to North America with a great product at a low price and watch some of the major US consumable companies offer a lower price and suptly threaten their distributors that if they take on your product line you will loose their product line. In America we call it "free enterprise" Good Luck

txtReplySubject:
RE: Ed what do you think about the flux cored market .


txtReplyBody:
PATRICK, visit the MIG alum section at the site and take note of the alum spray settings. Low to medium MIG spray settings make good pulsed MIG settings using 22 - 24 volts. Regards Ed


txtReplyBody:
I think those are the perfect Hobbyest machines.  I rent them for Welder Training all the time.  They will work well in Spray as long as you respect the duty cycle.  They are great for Short Circuit.  They run an 0.035 just fine.  The Rep. probably figured you weren't gonna buy 40 of 'em any time soon.  PWC


txtReplyBody:
250 AMPS IS THE TRANSISTION BETWEEN SC - SPRAY WITH AN 045 WIRE. TO GET STABLE SPRAY A LOW REACTIVE MIX LIKE ARG9N 2- 5% OXY OR 
ARGON - 8 OR 10 CO2 > 26VOLTS. The 035 WIRE WILL GIVE YOU SPRAY AROUND 200AMPS. I LIKE THIS POWER SOURCE ESPECIALLY WITH THE 035 WIRE, ED


txtReplyBody:
Thanks to Paul and Ed.
A lot of on-target information in just a few words.
Couldn't justify a 350P, but wanted above my 175,
and now know that the 252 meets my needs and then some. Thanks again.


txtReplySubject:
Level 2 weld inspector wanted on Ont Can


txtReplyBody:
Its a mix of silicon and manganese oxides that come from the elements in the weld and the reaction with the CO2. IF YOU WANT WELDS WITHOUT THESE OXIDES YOU WOULD USE ARGON 15 - 20% CO2 with 70s-3 wire.


txtReplyBody:
You get all the oxy you need from argon 15 - 20% CO2 (provides the same oxy potential as a 2% oxy mix).  A five percent oxy mix provides too much oxygen. Also CO2 provides additional weld energy from the gas dissociation properties, (oxy does not do this, oxy in contrast lowers the voltage requirements reducing weld fusion potential.


txtReplyBody:
you can use any temp stick just keep it away from the weld


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I say get yourself one of these Infared Temp Guns.  They are dirt cheap and far more convinient then the sticks.  From an inspectors point of view, measure that interpass/preheat 2-3 inches from the weld.  PWC(http://www.amazon.com/Temperature-Infrared-Thermometer-Laser-Sight/dp/B002YE3FS4)


txtReplyBody:
having een in the industry for 32 years both in Manufacturing and distribution, I concur with Ed's answer.  There will be repurcusssions from mainline manufacuturers. However, the product line you speak of has some advantages in that they profess H2 results in the 2.3, 2.5ml/100gms ... something no standard U n O type of cored wire can match. Are there persons/organizations willing to pay the price..?? I would argue that yes there are.

Without naming the company...I would say try their metal core at 22Volts - 175 amps Vertical Up ... on a std CV machine.!

txtReplySubject:
RE: Ed what do you think the market size would be for a seamless FCW product with about H2 levels


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I dont believe we had any Lincoln engineers  on the AWS comittee as we wrote the MIG gas specifications. The primary requirement for a MIG root if using pulsed MIG or modified SC is that you are trying to control a weld that bridges a gap. Any company including Lincoln that advices a weld shop to use a helium tri mix to weld a root is a company that is giving the worst possible weld advice. Helium mixes require higher voltages and provide more weld energy. thats the last two things you need for a root. Welding steel roots, simply select an argon 10 - 15% CO2 mix. If welding stainless roots simply use an argon 2% CO2 mix.

txtReplySubject:
RE: Ed Lincoln has told us the best gas for a root STT is..


txtReplyBody:
my advice for you is simple. Pick up the machine and place it next to the garbage. Regards Ed

txtReplySubject:
RE: I have a allstar mig and it does not have enough heat at the stinger. the heat setting is on high but  when an arc is struck it spatters and pulses fast and throws lots of sparks. will not penatrate the material.


txtReplyBody:
STOP TAKING ADVICE FROM YOUR WELDING SALES REP!  Good Gravey!  PWC


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the two letters BS best decribe the three part gas mixes, visit the MIG gas section at this site


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As both wires are subject to rust, the bottom line is you need to evaluate the weldability and its consistency from the weld wires selected a subject well covered in the MIG weld section of this site..

txtReplySubject:
RE: Difference between copper free and copper coated mig Wire


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the benefit is you cah get spray with this mix and use it also for short circ and flux cored. You cannot get spray with the 75 - 25 so what voltages are we taling about? All argon mixes that can attain spray typically achieve spray in the 26 to 31 volt range, Regards Ed

txtReplySubject:
RE: 84 Ar/16 CO2 voltage requirement vs. 75 Ar/25 CO2


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Ed, I've got no idea as to the voltage ranges or parameters Airgas refers to. They simply like to say, "It cuts the voltage required-in half". I've queried them about this--without response. I now suspect than this long standing claim is something cooked up by a sales manager who thought he heard something that he did not.


txtReplyBody:
The weld reality is >90% of what you here or read about on the subject of weld gases is sales induced and remember I was ob the AWS comittee that wrote the also sales influenced AWS MIG gas specifications.


txtReplyBody:
use tig weld to tack with monel 190 wire

txtReplySubject:
RE: Welding Monel Studs to A572 Grade 50 Steel Plate


txtReplyBody:
Allen,  Try common sense.   It is understood throughout the industry that most weld defects (70%-90%) are attributed to stops and starts.  We automate (or change from manual to semi-automatic) for the purpose of improving cycle time and quality.  Most of that quality improvement comes from the elimination of starts and stops.  Starts in welding can lead to overlap, incomplete fusion and slag inclusions.  Stops typically lead to cracks and undercut.  Some of these discontinuities may be considered acceptable but stacking them on top of one another in a multi-pass weld is just “flurtin’ with disaster”.  You could probably search the internet for an article on weld stops and starts and get plenty of horror stories.  But in that same search will be oodles of pixie dust salesmen with a simple wire/shield-gas/power source that can take all those troubles away.  Stick with common sense.


txtReplyBody:
all that data for thr last 10 years has been in my MIG process control and best practices process control program


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Just wondering how the meeting went.
PWC


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When I read that. Article I saw a picture of a root that looked like it was highly oxidized so if that's the best the RMD can do then I would warn pipe shops not to take too much notice of what they read. By the way when rotating pipe the regular short circuit process is just as effective as the RMD and the STT process

txtReplySubject:
RE: RMD stainless root without a purge gas


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The only benefit is to Miller who make a lot more profit from the RMD. When carbon steel pipe is "rotated", for the root regular short circuit with an 035 wire is as good as both RMD and STT. For the fill pass using the same wire and low end spray data will provide superior weld quality than pulsed MIG. All data available in the manual MIG train resources

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RE: ROTATED PIPE WELDS, Pulsed MIG versus Spray


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PWC:
At the risk of making Mr. Craig's head explode, might I suggest the "No Teacher Left Behind" educational set that Lincoln Electric produces?  It is not entirely a video per se, but it does have a very well thought out lesson plan that includes a rather extensive .ppt presentations for many different processes.  There are videos embedded in the presentations as well.  I don't know if this is exactly what you are looking for - but it is a great supplement to instruction.

txtReplySubject:
RE: Who sells the best basic training video for GTAW (Tig)


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Thanks Ryan.  I’ll check it out.  I’ve found there is a little something at Practical Welding Today TV (http://media.thefabricator.com/pwtv/), but I wish they went just a little more into detail.  Theirs is about 10 min and it seems like if they expanded it another 10 it would be perfect for my need.  P.S. Guiness may ‘B” good, but I’m a New Castle man… and when I’m broke I’ll always fall back to High Life.


txtReplyBody:
Let me know if you have trouble tracking down a copy of "No Teacher Left Behind"...I have a few copies and would be more than willing to share.  It is a 6-disc set and includes SMAW/FCAW/GMAW/GTAW/SAW/OFW.  
Guinness is my Black Lab and Guinness B. Good is his AKC name, but I stand by it as a statement or a name!


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use argon 15 - 20 CO2 - 035 70S- 3 WIRE, SHORT CIRCUIT Wire feed at10 O'CLOCK at (210 - 240 ipm) 17 VOLTS welding vert down

txtReplySubject:
RE: Having trouble on MIG root pass on 4140 pipe


txtReplyBody:
GO ON MILLER WEB SITE,  they have the best TIG train resouces and some of it is free


txtReplyBody:
I recieved the package from Lincoln Elect. yesterday.  Wow!  Very nice of them to provide to instructors at no charge.  (Whispering quietly so as to avoid lightning bolt...) I've always liked working with Lincoln Electric.  They've given me support for some pretty tough problems.  PWC


txtReplySubject:
RE: TIG welding 6061 al without filler metal


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optimum welds on this application are possible, this info is available under Ed's Robot Process Control Training resources at this site. Regards Ed

txtReplySubject:
RE: Welding 1215 Nut To A 1035 Threaded Stud.


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Poor choice of weld wire as operators won't like the current the equipment won't like the current and the welds won't like the current y

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RE: Transition currents for GMAW welding


txtReplyBody:
...in addition to Ed's comments...  To be considered "Prequalified" the current range needs to be "within the range recommended by the manufacturer" of the electrode.  Are you talking about using a 1/16th solid wire? or a 1/16th cored electrode?  A 1/16 solid wire application can be a Bear if you are using this as a semi-automatic, hand-held application.  But if it's cored this is pretty common.  I'm affraid you've given too little information.


txtReplyBody:
it sounds like something that has come out of the mouth of a salesman


txtReplyBody:
Yes, that's probably true because it's a book written by that big american welding equipment manufacturer. It's been written in the fifties. When I saw people doing SAW by hand in the book (close to insane but brought back up last year by Kjellberg) I thought there might be something serious behind vapor shielded arc welding. Maybe someone from the old times knows :-)


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i thought as i have been welding for more than 50 years you would figure out i am from the old times


txtReplyBody:
If I had said that before, you would have hit me in the neck :-)


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The procedure is called tip Tig at tiptigusa.com


txtReplyBody:
AWS D14.3 is most likely the right standard.  Strict adherence should cover you from a welding perspective, but your trouble will come from changes you make to the design in an attempt to do repairs.  This may very well be "more than you can chew".


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I would use alum bronze wire but your power source is too small


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if it meets your needs fine its not a product I would purchase Regards Ed


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I have never seen an application in which metal cored wires were necessary...


txtReplyBody:
attain my MIG robot process control data to optimize optimum welds on any application


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(http://www.weldreality.com/discussion/post_detail.asp?PostID=1442)  Allow me to share a previous post.  PWC


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I have made only 2 attempts to impliment metal cored wire in a robotic application.  Both, I retured to solid wire. Mainly due to feed problems. As for manual applications, I worked for a rail car manufacturer (ACF) where all interior welding was completed with metal cored wire and a pulsed process.  I was never able to get a solid wire to perform (no spatter/no bleed thru) as well as the metal core. It was 1/16 dia wire on 3/16 lap joints. ...and that wire was fed through 25 ft guns.  That application worked well, but I've not found one since.  That was 1996-99.  Maybe I just got better at setting weld parameters :-)  PWC


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You did not just say, "...the salesmen..." did you?  I suspect you already have the equipment you need in house. PWC

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RE: Best MIG process for rotating pipe root


txtReplyBody:
Take that low cost CV MIG power source. Get an 035 S70-3 wire. Set the wire feed at 10 o'clock. (210 inch/min) Set 17 volts. Use a 75-25 CO2 or 80 - 20 co2, Start in middle of tack Rotate pipe anti-clock wise set torh at 2 pm and forget about the RMD or STT equipment


txtReplyBody:
Good robot parameters may leave no spatter or miniscule spaater. Antispatter compound (water - oil) leaves welds with unnecessary weld porosity

txtReplySubject:
RE: Antispatter spray at robotic welding


txtReplyBody:
Ed I have put a table half way down the home page at tiptigusa.com with the weld benefit diferences, Regards Ed Craig

txtReplySubject:
RE: Differences between CMT - Pulsed MIG and TIP TIG


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As a result of the 21 volts the weld transfer would not have been short circ it would have been globular. The only difference between this and the pulsed is the pulsed is more stable, the droplet transfer more consistent and more frequent, however the weld energy would be very similar

txtReplySubject:
RE: GMAW-P Using 75 Ar & 25 CO2 Shielding Gas


txtReplyBody:
The purpose of the web site is to provide what I know and if it gets you lost and then hopefully you will purchase my MIG and flux cored process control programs that will DIRECT you to a sucessful weld career. As for SAW its nothing more than MIG welding with larger weld wires and instead of gas you use flux. Using my clock method, if you know optimum MIG WF settings for an 0.062 wire you will know the optimum settings for any weld wire


txtReplyBody:
Thank you for the quick reply. I appreciate the good information you make available on your site.


txtReplyBody:
Thank you very much for the info!!! I am not getting lost in the context but in the structure of the website, anyway I didn't mean to tell you how to do your job. Don't worry I'll buy another book soon :-)

Best Regards 


Uli


txtReplyBody:
It is not an essential variable, so a new PQR is not required, but a new WPS is.  That said... running the process in Auto without verifying the penetration profile would be foolish.  PWC


txtReplyBody:
If it's a short circ or spray weld you first set the wire feed and then provide the volts. If using pulsed you should also set the wire feed similar to the SC and spray settings. Weld personnel who set voltage first are typically personnel who have no understanding of weld parameters

txtReplySubject:
RE: Which comes first, the WFS or the Volts?


txtReplyBody:
With Ed I completely agree... but to the defense of the manual (semi-auto) Welder...  In a manufacturing environment using typical, no frills Mig equipment, The voltage is set at the power supply which can sometimes be well over 50+ft from the feeder.  But the feeder is typically the Mig Guns length from the Operator (Welder).  Under these common conditions, it is typical for the Welder to set the voltage, then climb on to/in to/up to the weldment and make adjustments to WFS to "dial-in" the welder.  I'm not saying it's the right way... I'm saying it is the "real world" way.  IMHO - PWC


txtReplyBody:
Paul again setting the voltage first shows a lack of process expertise, it does not matter what the length of cables are the voltage should be the last parameter selected.


txtReplyBody:
I hear ya... I'm just picturing these guys on a production line (examples: Welding inside a mixer drum, Welding inside a refuse hopper, Welding the roof on a trash hauler, or a covered hopper rail car...).  I can see how these guys evolve to setting voltage, then climbing to their perch, adjusting WFS, then hittin' it.  You're right, setting WFS and then adjusting voltage to "dial in" the arc is the right move...  I teach that in my classes.  I'm just adapting this to real world application.  I hope you're doing well.  I'm about to make a major move... Pipeline Integrity.  Should be interesting.  PWC


txtReplyBody:
Sad thing is...there are what are supposed to be educational welding websites out there that profess that you should set the volts first, then set the wire feed speed.  I was shocked and questioned my own understanding for a second, but I'm glad this forum brought me back to weldreality.


txtReplyBody:
Dear David,

One thing on salesmen: take half of what they say, multiply it by zero and you are close to the reality. Exceptions are seldom. GOOD pulse welding equipment (which is still not easy to find) can provide reduced heat input at the same deposition rate of conventional welding in the range of 10-20%. That is what most people base their argumentation on. Most of the times BAD pulse equipment produces just the opposite. Still the amount of fumes depends on surface contamination and most important on arc length.


txtReplyBody:
(i)If the correct consumables are used and spray transfer is set correctly, the weld fume differetial between a pulsed MIG and spray weld shpild be small. 
(2)If you want the lowest possible weld fumes consider TIP TIG.


txtReplyBody:
With your weld you will have the ductility you need


txtReplyBody:
Depends on application. Weaves are beneficial to prevent burn through on gage welds or bridge paps. Weaves are also benefical on fillet weld > 6 mm, or on welds that require the weld energy be foccused on a specific side of the weld.

txtReplySubject:
RE: oscillation during mig welding- good or bad


txtReplyBody:
Here are 2 articles I wrote on the subject...  http://its-good-to-be-me.blogspot.com/2009/03/what-are-negative-effects-of-whipping.html  http://its-good-to-be-me.blogspot.com/2010/09/what-are-reasons-to-oscillate-weld.html  PWC


txtReplyBody:
I have tried tri-mixes (both +90% He and +60% He), and varying mixtures of 98%Ar with 2% CO2 or 02.  The 98-2CO2 was the best gas mix for both short circuit and spray of stainless.  The 97-3 should work well, but you may have to turn the inductance up for SC of Carbon/Stainless as there isn't much energy in that mix to facilitate fusion with that low energy mode of transfer.  Of course, at the end of the day, you must do some testing as to what effects that level of CO2 will have on your corrosion resistance or performance at elevated temps - if either of those constraints fit your function of the weldment.  1 test is worth 1000 opinions.


txtReplyBody:
The number one issue with spray and pulsed steel welds is either marginal fusion or lack of fusion, weld energy comes from the reactive CO2, so use 10 to 20percent CO2 for steels. To minimize carbon pick up use 2 to 5 percent Co2 for stainless


txtReplyBody:
Dear Ed, what is your opinion on oscillation while weld root at fixed pipe (horizontal axis) with classic short circuit transfer, 1.0 mm wire, Ar+15%CO2 (no STT no RMD). Just straight dragging vertical down or moving the gun from one side to another?


txtReplyBody:
If you have some coin, get with a Fronius rep.


txtReplyBody:
Of course a lower energy process produces less fumes as it also produces inferior weld fusion. Steel MIG weld fumes have been studied for decades with no conclusions. If you are welding alloys you use fume removal equip and consider TIP TIG


txtReplyBody:
What I want to know is how does a person get a job like yours and what management would ask for info on a subject which has six decades of studies completed


txtReplyBody:
We tried a regular CV MIG 400 AMP machine we got good results. Last we tried Miller  RMD machine, in which I didn't see any difference from the lower cost CV Machine. I believe now in what you say on your website, that low cost MIG equipment and process knowledge will get the MIG and flux cored weld quality and productivity we need. Which MIG process control training materials should we purchase and thanks for your advice and help.


txtReplyBody:
In the old days when a person wanted knowledge they went to look in "books" . If you like many want to play around with a weld process that is resposible for you pay check, then avoid the books. However if you want to become a proffesional in what you do I suggest you look at the self teaching weld process control books and materials available at this web site.

txtReplySubject:
RE: setting welding machine volts and wire speed


txtReplyBody:
One thing consistent with the weld industry is The BS never ends.


txtReplyBody:
14 years ago using regular lower cost CV equipment, increased wire stick out knowledge and low energy gas mixes I was getting 60 to 80 inch/min, 3mm, stable welds without spatter. This data is in my 'Maanagement Engineers Guide To MIG" book available at this site

txtReplySubject:
RE: Unique results fron Inverter power sources


txtReplyBody:
What a snob.
I welded for three and a half years, flux core and mig, had a leave of absence for a couple of years, merely asking to refresh my memory as to the settings, don't need instruction on how to weld nor a lecture on welding.


txtReplyBody:
"...don't need instruction on how to weld nor a lecture on welding..."  David, you asked for advice and were given some of the best advice of your career.  All you have to do is take it.  Peace! PWC


txtReplyBody:
The solution is simple it's called TIP TIG


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Stan the gas is a con job, use argon 10% CO2 and also you are using  a 70S6 wire which will create unnecessary oxides and add to weld start problems. You have invested over 150,000 dollars on the equipment I recommend you spend 295 dollars more on my robot process controll training program and you will no longer be buying into the bs that inundates  this industry Regards Ed

txtReplySubject:
RE: Do we need a three part helium tri mix for steel welds


txtReplyBody:
[1] TIP TIG typically provides > 200% more weld
[2] TIP TIG is suited to all applications where as CK is extremely application limited and highly sensitive to torch movement.
[3] TIP TIG faster speeds produce much lower weld heat that provides less distortion and superior mettalurgical properties.
[4] TIP TIG always provides superior weld quality.
[5] TIP TIG uses much less weld gas


txtReplyBody:
you have the usual wire feed issues associoated with the 4xxx series


txtReplyBody:
This subject is covered extensively in my process control education and training resources at this site Regards Ed

txtReplySubject:
RE: Welding cost for GTAW, SMAW,SAW,& MMAW


txtReplyBody:
The answer is no you don't need the more costly balance wave Tig equip with its bells and whistles for you alum applicatins The weld reality is  on alum parts over 5mm, if you want the best cleaning action for the removal of the alum oxides (for lowest alum porosity) you will have to have 50 % reverse polarity which is the RP amount you attain with any low cost  TIg equip with AC . As for welding on thinner alum if you use the correct size tungsten and know how to manipulate a foot control you will get the alum weld quality you desire


txtReplyBody:
My prefence is under 3/16 pulsed MIG over 3/16 spray with 046 or 1/16 wires.


txtReplyBody:
Not much information on part thickness , process or parameters but lets assume it's thin gauge and in that case the oxide reaction is occurring because the part  heat behind the weld is still hot enough to have a reaction with the atmosphere. Best way to reduce oxide is weld faster


txtReplyBody:
We did not need costly mig equip 50 years ago for galvanized and we don't need it today You should get the results you desire with a low cost CV power source that  has an interface for the robot, straight CO2 and a E70s-3 wire Mininize the fore hand angle


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In Europe, for zinc-coated plates, mostly in car industry, it is used either MIG pulse with CuSi3 wire or even very expensive CMT (I guess with zinc based wire). Both CuSi3 and zinc based are non-corrosive and there is no need for re-coating with zinc. But, for other application it is used ER70S-3 (as said above) in Ar+18%CO2, but they apply zinc later over weld seam, either zinc itself or some paint containing zinc. It is a matter of cost analyse, to sum all costs and to find the best solution.


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With Tip Tig we typically use from 0 to 200f and we get no cracks


txtReplyBody:
I should probably add that much of the welding will be round tube so continuous 360* welds will be ideal. welding schools


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It's this simple. When the Chinease manufactures prove that they can consistently deliver a mig wire that is always within the chemistry and AWS requirements then you purchase the wire. From my personnel perspective and experience, if I had to use Chinease  Mig wire I would not sleep at night


txtReplyBody:
I have waisted soooo much time trying to prove to "bean counters" the need to purchase quality, consistant wire it makes my eyes bleed.  By comparison, Chinese Wire for Weld process would be like a bean counter with a calculator where the "4" and the "+" key didn't always work.  PWC


txtReplyBody:
It sounds like the typical weld shop nightmare. There is no advantage to using any flux cored wires larger than 1/16 as the required weld current for deposition is so high that the welders will use lower current which is manageble but produces low depositions, and in your case extensive spatter and weld fumes that are not doing your lungs any good. Ignorant weld management buy into large wires as they think welders will produce more weld. There is a shortage of welders in the weld industry if you are any good, find a weld shop where sanity prevail, where weld quality means something and the health of the workers is important.


txtReplyBody:
Dear ED, which Stellite 6 wire do you feed with TIP-TIG? Flux cored? Which gas do you use? Pure argon?


txtReplyBody:
Dear friends,

from a welding quality perspective I totally agree with all of you. We should be as careful as possible. But having just visited Europe's largest consumable production plant I found out that ALL wire manufacturers get their raw material from China.

It seems the welding world is stuck in the good old days we wish we once had. Looking at products like the iphone we see that China is capable of producing things that meet our quality standards. We just have to watch them closely enough and of course pay for what we want.

We should not be blinded by a spool of wire that has blue red and white colours on the box and believe it comes form the U.S. just because we paid twice as much for it.


txtReplyBody:
Thank you its nice to know that someone out there appreciates this stuff. Good news, you would be wasting money on the STT or RMD for your rotating IG open roots. Use instead your much lower cost CV MIG power source with this data. Wire 035 70S-3 - Gas Argon 20 CO2. Wire feed set between 10 - 11 o'clock, 240 ipm with 17 volts or as I like to teach 10 to 11 o'clock with 17 cups of cooffe, Use a 1/8 gap with an 0.080 land. Start and finsish on the four tacks 20 mm in length placed at 12 - 3 - 6 - 9 oclock. when you land in the middle of the tacks blend tack overlaps with grinder. Hold torch at 2 pm welding vert down and these welds will be as good as any RMD - STT root welds.


txtReplyBody:
Why are you concerned about weld cost and you are focused on part of the weld that costs the least. Real weld costs result from focussing on the fill passes and the fact that you are not using gas shielded flux cored tells me a lot. The Stt process is simple to use and as long as you can provide the required 
Root gap and ID alignment (which is rare on field welds)is OK that's fine   My advice would be use the smaw process for the root and fcaw for the fill


txtReplyBody:
You want ductility so use a E70T-1 ot E717T-1

txtReplySubject:
RE: fcaw filler wire for AISI 1026 to AISI 5065


txtReplyBody:
Dear Evan,

with these parameters you should be in short circuit. You are welding pretty fast (if the figures are correct) and using very much shielding gas. Since when do you have the problems, has any systematic change occured? Give more details on your process (wire/transfer).

Regards Uli

txtReplySubject:
RE: Robotic MIG Welding Porosity Problems! Help!


txtReplyBody:
I feel sorry for anyone that has to work with Panasonic equipment First this question is addressed in my Robot Best Practices Program The bottom line is the weld size and weld energy is likely insufficient Small thin welds welded to quickly and you have a trap for porosity


txtReplyBody:
Go with the miller the reasons are in the web site under Mig Equipment


txtReplyBody:
With all the problems in this industry you are concerned about this subject, sorry I need to get a life.


txtReplyBody:
Visit the MIG equipment section, this pulsed MIG BS has been going on for more than a decade. My robot process control resource provides soulution for this Miller poor pulsed MIG equipment performance.


txtReplyBody:
Expect the same performance from both go for the lowest price and also take into consideration who will give you the best support if something goes wrong (these however are pretty rugged units)

txtReplySubject:
RE: Esab migmaster 280 pro  v's  millermatic 252


txtReplyBody:
Ben the simple answer is "none" but in contrast  to MIG wire the MC wires will increase your weld wire costs. As this subject is covered in the flux cored section I wont waste any more time on a subject that at this time should not be taking place in any weld shop that prides itself on its weld process expertise.


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Visit the pulsed MIG section I provide the prime reasons why pulsed is good for some automation and poor for many manual welds Regards Ed


txtReplyBody:
It frustrates me that you would not go gas section of this site, If you are using MIG on satinless the CO2 max due tocarbon pick up is 5% CO2 with flux cored 25% CO2 is norm


txtReplyBody:
[1] You go to this web site and click on all weld and steels programs, [2] you click on MIG gas information and the answer is there.


txtReplyBody:
Greg there is data in the MIG gas section on the inconel mixes. If you get a chance try TiP TiG on these alloys as its far superior to any MIG process If you have questions call me at 828 337 2695


txtReplyBody:
Keith you are not using the corect wire size, coorect data and correct techniques to do this simplw SC weld. The answers are on this web site under MIG < 4 mm.


txtReplyBody:
Well Ken as much as I am a proponent for good quality weld wire and good contact tips, I would like to remind you that chicken fence wire, two car batteries and cheap contact tips would get better results than they were attaining. The biggest influence on a robot mig weld made with an argon mix is the weld parameters and techniques used. The poor weld wire can cause arc stability and weld inconsistency, and there are many levels of poor wire. As for the contact tip, the bore size size and again the parameters will have the most influence...


txtReplyBody:
My solution is a simple one I would turn the pulsed mode off and use the more constant energy spray mode with a 60 He - 40 Ar gas mix Regards Ed

txtReplySubject:
RE: Pulsed MIG aluminun, fusion and porosity


txtReplyBody:
You could try providing the data necessary for me to answer that question

txtReplySubject:
RE: Proper way to weld a 36 plate to ASTM A519 grade 1026 hot finish seamless tube


txtReplyBody:
You look two inches below this box and select the book you need

txtReplySubject:
RE: how to set a mig welder for welding thin gauge stainless steel


txtReplyBody:
Apart from a slight increase in strength there should be no issues


txtReplyBody:
could you spare a few more words to describe what you are doing along with the process, consumables and procedure data

txtReplySubject:
RE: cold lap how can this be achieved on initial stringer


txtReplyBody:
Why would you use that rubbish when tip Tig is available

txtReplySubject:
RE: Stainless Steel FCAW innershied - NO More!!!


txtReplyBody:
Bottom line is  use E70S-3 as it has low silicon forget the Japanese claims as they are nothing more than blatant BS and use argon 15 CO2

txtReplySubject:
RE: Galvanized Galvanealed and Japanese consumables


txtReplyBody:
I hope before I pass on to the next world which hopefully be a place that does not have bull shit that the MIG welding industry will get this message, If I can take the cheapest MIG machine and make it perform as well as the most expensive MIG machine, then I can also take the cheapest contact tip and make it last as long as a CuCrZr  or silver plated tip. Most tip issues have less to do with wear and more to do with lack of process expertise and you know the solution to that

txtReplySubject:
Special MIG  contacts tips and weld benefits


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Bryson order the standard argon with 2 percent oxygen it should be a common low cost gas mix. By the way I developed that low cost argon 2 CO2 mix 25 yrs ago and it's still the best gas mix for stainless. I offer a pox on all gas distributors who are ignorant and for decades have mislead the weld industry Regards Ed


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Setting weld data has nothing to do with efficiency or with a welders preference. The Wire feed is selected first based on the desirable weld transfer mode and the weld speed (deposition) required. The weld voltage is then set to deliver the current required and depending on the weld mode the arc length desired

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RE: Robots Wire feed or voltage setting?


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You can not use co2 for tig welding. If you are tig welding the tube, use 100% argon. If you are mig welding, you might be thinking of C8 gas which is 92% argon and 8% co2. A C5-C8 would be ideal for what you are trying to do. Even C25 would work.


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Will we assume he's talking about mig welding ...


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By the way Will your answers reveal you have not been to the mig gas section at this site and most of what you stated is incorrect Regards Ed


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can tip tig be used on aluminum and other non ferrous metals?


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Many limitations for common applications if you want further advice I can discuss this with you my fee payable through pay pal is $350. You can then call me at 828 337 2695 Regards Ed Craig


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Those weaving parameters  I would likely utilize for cladding  To miniimize weld dilution I am a great believer in making welds that require consistent weld fusion in the 1/4 to 3/8 fillet size range . In this range the amount of deposition typically 12 to 14 lb/hr versus the weld energy and travel rates can obtain an optimum balance.


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Check out item 4 in my self teaching and training resources it's all you need for your down time,quality and productivity issues


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Dear Ed,
Thanks for the input, it is just what I thought. If the weld sequence is changed to a number of smaller welds I guess arc sensing on a non-symmetrical weld surface will become more diffucult. Could you share some experience/ advice on this. Thanks in advance!


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You have more than gun nozzle issues call me 828 337 2695 Regards Ed Craig


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Companies like Tweeco used to sell HD heavy duty nozzles which provided a little better heat sink thsn the regular thinner nozzles However keep in mind with the increased weld duty cycle time from your robot the bottom line is you will likely have to switch to a water cooled gun and then the regular nozzles are fine


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I was thinking about the type that guides the wire when the stick out is increased.


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With a short tip recessed inside that regular nozzle approx 3/8 and a nozzle to work of 1/2 to 5/8 your average WSO will be 3/4 to I inch and that will have a sufficient current reduction for your app


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The 3 issues you will have with this thin gauge stain application will be oxidation, distortion and burn through and the sales rep advices that you use the worlds hottest gas mix Take note of the Mig gas section at this site and keep that sales rep outside the shop


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Use 035 type 308  and for the 304 to steel use 309 best gas mix argon 2 percent co2 check out the stain section at the site and also the mig process control materials so no one is playing around with the mig data . Tip Tig is not rented Regards Ed


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Simon unless something drastic has changed in pulsed MIG electronic technology assume the following. Traditional spray from CV equipment typically with "controlled weld conditions" deliver approx. 10 to 15 lb/hr. Pulsed MIG at the high end of this deposition range will often be slightly erratic and can produce poor weld width to depth ratio,(as discussed in pulsed section). However if you are interested, in my Management Engineers Guide to MIG book I devoted a chapter to improving spray deposition rates with extended wire sticks outs WS0 which allow much higher deposition while keeping the current in a range in which the electron flow remains stable. One guy I know used WSO logic,has for the last decade averaged 20 to 25 lb/hr with CV spray transfer on a similar robot welds. Any questions email me Good Luck Ed

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RE: Pulsed Mig or regular mig for highest deposition


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Dear All,
Having  worked in the R&D department of one of the oldest GMAW equipment manufacturer (neither red nor yellow :-) I have seen almost any pulsed power source available. If the names include “*iller, *ncoln or *bart” CV is the better choice.  Having developed pulsed machines I am of course a fan of pulsed MIG but still think Ed is right with the statement that for most carbon steel applications pulsed MIG has no benefits. 

With highest deposition MIG overheating the arc and puddle is the biggest concern. This is why a longer stickout is used. With a GOOD pulsed power source it is possible to achieve a stable arc beyond 20m/min of wire feed and reduce the effective Energie P=U*I by 20% compared to reg. CV. Therefore the power source should come from Austria or Germany.

Too many characters :-)


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In case twin wire is a topic there is no other choice but pulsed.

In case qualification of personnel, technical demands and budget is low I completely agree with Ed.

But as this is a new investment why not consider SAW on a heavy duty robot? There are only a few installations out there but they combine all degrees of freedom with a stable process.
Open discussion!

Regards Uli


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That company I told you about was in Australia making rail road cars and attaining  on average with many robots approx 25 lb hr with 450 amp CV power sources and using my wire ESO recommendations. This CV method is I believe still  the best approach to the rail cars  in which most of the welds are on parts less than 10 mm. Also when the higher weld speeds are required typically spray with the ESO recommendations should be more stable than Pulsed . I believe that SAW is not the best choice for this application so at the end of the day see what you can achieve with either pulsed or spray using an 045 wire and argon 10 -  15 percent CO2


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For fillet welds (that means no HV and no full penetration) on plates thin like this I think you are right.


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The operating temp limit for that 304 tank was 800F and that also applies to the 308 filler. This type of application requires more alloy and that's why the 316 was used. All the info you and your contractor need on this subject has been available for at least a decade in the stainless section of this site.


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John why don't you use mig short circuit with an 035 wire set wf at 300 ipm (10 - 11oclock) with 17 - 18 volts use argon with 2  - 5 Co2 It's a simple application Good luck..


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I would prefer the SC mode as the arc goes on and off therefore this mode is capable of providing less weld energy than the open arc pulsed mode. Remember with gauge welds the primary weld concerns are typically burn through, distortion and oxidation and the process that provides the least weld energy will provide the most solutions..


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As this site mentions in the pulsed MIG section (at least 50 times) in terms of dollars spent, OTC makes the best pulsed MIG equipment and with robots, for the last decade there has been very little difference between the robot manufacturers


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I would imagine an 8018C3 or if no post heat just use a 7018


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Hi Jon,
if this configuration has worked well before there might be a thousand reasons. Check the whole unit. Here are a few topics: Wire: cast, helix, batch (maybe only wrong label), surface (run through a paper towel). Feeding: rolls, liner (does not have to be teflon for steel, clean it with air), contact tip, torch (maybe it leaks cooling water). Electric parts: bajonet connector loose, grounding, cable length, check the read out (compare with Eds tables). Shielding gas: what type, too much or too little, hose......

If all this looks sound it might be the rectifying unit.  

Good luck.

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RE: excessive spatter, sooty welds, inconsistent arc, hard welds


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Jon about one inch above where you insert the question there is information on how you ask a mig weld question For example when you provide parameters that's what gets me motivated to provide advice


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RE: Tip Tig on 13 ft. Longitudinal P1 Fillet welds


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It is about keeping dilution between the two materials in an uncritical range. Check the WRC1992- or Schaeffler- diagram and make sure you do not end up with a martensitic structure. In many cases 1.4370 or 18 8 Mn type wire helps.


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All info at nickel alloy section of this site

http://www.weldreality.com/STEELS%20NICKEL%20ALLOYS.htm


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I wrote a book on the subject,and that book would get you through any weld MIG or flux cored weld test. So look at Eds weld training materials


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Well first the fact that you will be using 25% CO2 is not good as the optimum spray results come from gas with 25% CO2 which of course you would know if you read the gas section or my books.So you will get with the 035 wire results from  all positions on the wire feed control. Two easy ones for gage welds set WF 10 - 11 o'clock 17 - 18 volts for parts over 3 mm set the WF at 2 - 4 o'clock at 28 - 30 volts

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RE: What is the typical parameter range on a welding machine for 3/8 carbon steel plate using GA with .035 Mig wire using 75Ar/25 0 gas


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Yes you can however unless those TIG welds are defective you are likely wasting your time. Remember on parts with two differnt thickness the weld needs only to be the size of the thinnest part

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RE: Adding weld material over a tig weld


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As mentioned in the pulsed mig section Pulsed is a logical process for alum tho offers no benefits when the alum is thicker than 4 MMM With alum over 4 MMM the conventional spray mode will offer superior fusion and less porosity If you need to learn pulsed mig process controls the training resources are at this site

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RE: shipyard contractors ,aluminum mig welder ads


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Ed,I agree,I have been studying your web-site for years,I meant "scary" that the local shipyard weld management is buying into the pulse crap. I know at 1 big yard here they use nothing but Lincoln electric "new & improved" flux-core.


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If the shipyard weld management had an ounce of common sense they would recognize that from a welder perspective the pulsed mig process is no different from the regular mig process. And from a process controll process the average welder plays around with the regular CV Mig controls and they will play around with the pulsed controls. This is simply more evidence of the lack of good weld management in many ship yards.


