Welding Tips and Tricks

I am trying to tig this rod to the engle iron frame. The rod comes from Home Depot and tag said steel.
I grounded at the opposite corner of the frame.

I have tried several angles, increasing/decreasing gas flow and amps. No matter what I do, the end of the rod will turn cherry red/molten, but the angle iron will not pool. Each new try I cleaned rod and angle iron with steel buffing wheel on grinder.

Pictures are attached of my last try. One other thing amps on welder where same setting I used to put the angle together (100 A) setting but never needed to push petal all the way down.

The angle will carry heat away much faster than the end of the rod. You should keep the arc focused on the angle only, to establish a puddle, and feed rod to build that puddle, until you are close enough to tie the rod to the puddle. Once they are tied together, stop, and do the same for the opposite side, so you are firmly tacked on both sides of the rod. To weld it, start at a tack, heat focused on the angle again to establish a puddle, feed some rod and "push" the puddle up the tack to the rod, rather quickly, then back to the angle. The more connection you establish between the rod and angle, the more heat-flow path the rod has, and the more "normal" the weld will feel.

It's one of those "practice and accumulate experience" things that'll feel natural once you've done it.

Someone once told me, experience is what you have five minutes after you needed it...

Steve S

I tried several times to focus the arc on the angle but I kept getting the same results.

Another problem I had was getting torch, rod, angle and filler to come together with me in a comfortable position too.

I agree that's an awkward position to put everything in place. I think I'd set it on edge, and do it as a vertical weld.

If you're having trouble with the arc wandering to the rod when you want it on the angle, you need more stick-out, so the tungsten is closer to the "work". You need the tungsten quite tight in the joint for this. Don't fret if you dip it, or even stick it, this is not a "critical" weld. Just practice getting the arc as tight as you can.

two cents...

Steve S

It's practice and not Practice. I was hoping to use this as a basic portable welding bench. Im stressed for space in my garage so i was hoping this would be a good first project...

The welds don't have to be perfect for that. Hell, they don't have to be pretty, as long as it serves your purpose.

Every weld is an opportunity for a bit of practice, though, and worth paying attention to.

What I saw in your pictures should stand up to a sledge-hammer test.

Steve S

Heat up and flatten the ends of the rod where they contact the angle. It will form more of a lap joint and be easier to see and wash to.

I actually like the idea of flattening the rods, hadn't thought about that because I have something like 60 of the things I need to weld to this thing, but if it works I'll do what it takes.

I will try to stand it on end tonight. It's going to be a little tricky to do for me because I don't have much in the way of jigs I can use with hot metal right now but I will figure something out. I assume that by extending the tungsten out more I will need to increase the gas flow as well to keep good coverage?

While it's good to practice on anything non critical especially with a new machine - I gotta say - this looks a perfect project to practice MIG on ! sometimes Tig is the process of choice but honestly 60 odd of these is like tacking mesh to a frame - MIG would be the way to go.

Michialt,

Unless you're welding where it's breezy, you won't need more gas for more stickout. With tamjeff's excellent suggestion, you only need enough stickout for good visibility, anyway.

Noddybrian has a point, as well, about the quantity being better suited to MIG, but I assume you want the TIG practice here, where the finished product of your first few attempts are "less than visible", and time is not a factor.

Steve S

I agree that Mig would be a better choice. I could even use Oxy as I am most comfortable with it over Mig.

The absolute ONLY reason I am using Tig is to help develop the muscle memory for holding the torch, and to help me to learn to see how the Tig pool develops and how to manipulate it.

Sometime in the next few weeks I need to start working on a project for my fiancé and Future father in law. I have been asked to build an Ataud (aka cajun microwave or Chinese grill). i have to build two of them, and the request is to build them as light as possible. I've attached a picture of my Father In Laws current one.

To build this I need to be able to weld stainless for the inside where the food is cooked, aluminum for the overall fame and cart, and steel for the fire pit and grill top. I can handle the steel with no issue, but stainless and aluminum are both new territory for me.

To add a little pressure to the project, the main thing they will be cooking is Cabrito which costs about $150 each. If that wasn't enough, they usually have 15 to 20 pounds of charcoal burning on top, or they have burning Mesquite on top. So if I don't do a good job, and my design/build fails I risk it falling on someone and causing serious injuries.

Otto Nobedder wrote:Michialt,
Unless you're welding where it's breezy, you won't need more gas for more stickout. With tamjeff's excellent suggestion, you only need enough stickout for good visibility, anyway.

Noddybrian has a point, as well, about the quantity being better suited to MIG, but I assume you want the TIG practice here, where the finished product of your first few attempts are "less than visible", and time is not a factor.

Steve S

Okay...

I just looked up "Ataud"

That's a bit morbid from my perspective, but I understand it (in principle) now.

Do you have a particular design in mind? To see your plan will help with the advice you receive...

Steve S

I agree that calling it a coffin is a bit morbid. Even more so considering it's size...

I grew up in Iowa, and the first time I had Cabrito I was a bit reluctant, especially after learning it was baby goat. But I have to say it definately now a favorite.

Anyway, my plans are to build top down. The top is basically a grill. The fire pit is basically a 3" deep steel pan, and the grill top is an angle iron frame w/ steel rods for the grate. The "oven" I'll make from stainless. Basically there is little weight savings in these areas.

I'm planning to build the stand and the rest of the frame from aluminum. The wood in the picture 1" planks. Im going to use something like Birch that is routed to a good fit to help insulate the oven.

I'll be honest though, for this first build I'm going to wing it as I go. I doubt I can save as much weight as they are asking, but I'm estimating 30 to 40 pounds in saved weight.

I've eaten most of the domestic and game animals on the continent, including goat. I've eaten things some don't consider food animals at all. I've eaten the continent's largest predator, and I've eaten snails.

The purpose of this cooking apparatus only makes me wish I were close enough for an invitation! The name does not put me off, and the intention interests me.

As I understand it better, I'll offer any advice I can for it's assembly.

Steve S

Is this the jist of it?
Steve S

"Dutch Oven mates with Barbeque Grill!"

That picture is exactly it.

After todays experiments in the garage, It may take me a bit more time that planned. I made several attempts at welding some 20ga stainless, and it didnt go so well. I learned that it dont take much to burn through this stuff.

Tomorrow Ill pick up some Aluminum angle to use as a jig/heat sink wand try again.

Aluminum is a good idea.

20 ga. SS is a challenge for experienced welders, if they don't do it regularly. I rarely weld below 16 ga. and have a hard time keeping sugar off the back side.

Steve S

I do need the practice with Mig too, but right now I need as much Tig practice as possible. This project involves mild steel, stainless and aluminum. I have to build two if these with the first being for my fiance and to be used at home.

This first one I am using all mild steel for most of it, but I still need stainless too.

As for this post, I took a step back and started over. This time I made sure every surface was clean, and things went better. I took extra time to get my corners a perfect fit.

The cross rods were cut to have a max gap of 1/16" max. I initially tacked the rods at the ends to the angle. Then I come back and tacked them long ways on both sides of the rod. then flipped the assembly and mad another tack where the rod and angle meets... Massive overkill for a grill top, but the practice is helping me.

Now with the assembly 95% finished everything holds good. Only issue that I am not happy with is that on several of the underside welds I allowed the angle to get a little too hot and the top is not real smooth. Later I'll see if I can use the grinder to clean things up.

Now the next step in this project is actually a little easier for me. Basically I have to take a 2x2 angle and weld a 1x1 angle to it creating a "z" the cut 45s to create a frame. The weld in a steel plate to fill the frame. This next part is a "fire pit" that this first mart sits/hangs over.

Im pretty confident that I can do the next step pretty easily. It will give me a lot of practice on butt joints. Again this would be perfect for mig, but im gonna use it for practice with tig.

It sounds like, on the whole, it's going really well.

I'm glad!

Steve S

I can't say my welds look great, but at least I am confident that they will hold for their intended purpose. I had previous experience in learning welding, so my expectations aren't too high. I know that learning the basics and practicing them is the biggest key.

I've said it before, I'll say it again.

We like to call ourselves craftsmen, so we tend to be our own worst critics.

It's true. We'll beat ourselves up over a weld other folk will compliment.

Steve S

I doubt there would be too many compliments on my welds so far... Unless "WOW that really holds" counts.

More serious, I tend to be reasonable when I judge my own work. I've spent most of my adult life with the philosophy that I should never stop learning new skills. i've never been afraid to tackle a project just because I didn't know how to do something. Because of this I have probably done more than most others my age. I figure that the day I decide to stop learning will be the day that my living will comes into play.