Advice Welcome - Page 2

bigworm40 · Tue Dec 09, 2014 2:23 pm

Understood, now if I could only keep this piece flat rather then Turing into
a "U"

Tue Dec 09, 2014 2:47 pm

Keep skipping around, from one side of the job to another. And maybe bolting it down to a strong back. Or if you have more than one of these parts, tacking them back to back and weld them both in the same operation so that they counteract the shrinkage forces.

Superiorwelding · Tue Dec 09, 2014 3:18 pm

Here is the other discussion we had as well as the link again.
http://www.lincolnelectric.com/en-us/su ... welds.aspx

http://forum.weldingtipsandtricks.com/v ... cks#p29353
-Jonathan

bigworm40 · Thu Dec 25, 2014 10:28 pm

So I finally picked up all the parts to convert our 252 to run .045 wire. This is a picture of the third vertical uphill weld I ran with the new wire and c25. I struggled for along time with vertical up but I think I have been improving. Would love to hear all of your thoughts. All three pictures are of the same weld.

Fri Dec 26, 2014 12:17 am

Good solid start. Seems as though your movements are all nice and even. With flux core wire, it is important you don't rush across the middle (you're not doing that by the way) but hold the corners for a good pause to avoid under cut.

AKweldshop · Fri Dec 26, 2014 12:33 am

Personally, I wouldn't weave.
Just straight up stringers.

Here's a few of my practice beads.
The first pass, and two on top, for the vertical t-joint.
And that's padding beads on the right.

bigworm40 · Fri Dec 26, 2014 6:13 am

That looks very nice. I find if I don't weave the weld just piles up and looks horrible.

AKweldshop · Fri Dec 26, 2014 3:11 pm

What are your settings?

Volts, wfs, and are you using .045 wire?

jwright650 · Mon Dec 29, 2014 9:27 am

AKweldshop wrote:What are your settings?

Volts, wfs, and are you using .045 wire?

bigworm40....also include your gun angle when you answer AKweldshop's other questions.

bigworm40 · Thu Jan 01, 2015 8:22 pm

Hey guys sorry for the delay in responding i don't think i got the notice that there were more replies.

23.8 v 350 ipm .045 75/25 and my gun angle was steep in the up direction. Since changing over to the .45 and 75/25 i haven't tried running just strait up with no weave, when i return to work on Monday i will give it a shot and let you know how it goes.

AKweldshop · Thu Jan 01, 2015 9:20 pm

bigworm40 wrote:Hey guys sorry for the delay in responding i don't think i got the notice that there were more replies.

23.8 v 350 ipm .045 75/25 and my gun angle was steep in the up direction. Since changing over to the .45 and 75/25 i haven't tried running just strait up with no weave, when i return to work on Monday i will give it a shot and let you know how it goes.

I'd be more like 275-300ipm.

And you don't need much uphill push angle, not more then 5-10 deg.

That's what works for me....

~John

bigworm40 · Thu Jan 01, 2015 9:26 pm

weldin mike 27 wrote:Good solid start. Seems as though your movements are all nice and even. With flux core wire, it is important you don't rush across the middle (you're not doing that by the way) but hold the corners for a good pause to avoid under cut.

It seemed to me the longer i stayed in the corner the more undercut i got. what kind of stick out do you look for?

bigworm40 · Mon Jan 05, 2015 10:05 pm

AKweldshop wrote:Personally, I wouldn't weave.
Just straight up stringers.

Took your advice and ran strait up stringers, they looked great and felt great. Its such a good feeling when your running bead and you lift your helmet and chip the slag and it looks as good as it felt. I didn't have a chance to get any pictures but i will tomorrow and i'm going to try my hand at some etching also. will post pictures tomorrow. I wish solid wire was as easy uphill as fluxcore.

Mon Jan 05, 2015 10:54 pm

Good to hear about your success. But still put practice into weaving because one day you might need it.

AKweldshop · Tue Jan 06, 2015 1:32 am

bigworm40 wrote:
AKweldshop wrote:Personally, I wouldn't weave.
Just straight up stringers.
Took your advice and ran strait up stringers, they looked great and felt great. Its such a good feeling when your running bead and you lift your helmet and chip the slag and it looks as good as it felt. I didn't have a chance to get any pictures but i will tomorrow and i'm going to try my hand at some etching also. will post pictures tomorrow. I wish solid wire was as easy uphill as fluxcore.

When you got it set right, your slag should just fall off in one piece....

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AKweldshop · Tue Jan 06, 2015 1:35 am

Here's an excellent video from Miller on running duel-shield uphill.

Great arc shots.

https://www.youtube.com/watch?v=lKAJPyFOeVc

bigworm40 · Tue Jan 06, 2015 9:37 pm

That video was great, made me realize My stick out was way to long.

So something I have noticed with using fcaw-g and the 75/25 is that it puts off a different taste or smell then my mig wire with 92/8 im used to running, so much so that i feel like its harder to breath around it. It's almost a sweet smell but then sometimes its like i hit a pocket of something bad and fumes are so bad it hurts my lungs. Anyone know anything about this? I bought one of those miller respirators that go under your helmet and the fits not that great and i do have a beard. when i do the "fit test" im good but i cold still taste smell that nastiness.

Braehill · Tue Jan 06, 2015 10:10 pm

Bigworm,
I couldn't give a guess to what the nasty smell is, but the sweet smell is probably Ozone (O3) and it's not harmful in small doses. It's what you smell following a nearby lightening strike. It happens in the arc as the Atmosphere is being ionized. That's not the most scientific explanation, but you can research it on the interweb if you'd like.

Len

Tue Jan 06, 2015 10:33 pm

Flux core wire has some real nasty crap in it.

Coldman · Tue Jan 06, 2015 10:49 pm

bigworm40 wrote:That video was great, made me realize My stick out was way to long.

So something I have noticed with using fcaw-g and the 75/25 is that it puts off a different taste or smell then my mig wire with 92/8 im used to running, so much so that i feel like its harder to breath around it. It's almost a sweet smell but then sometimes its like i hit a pocket of something bad and fumes are so bad it hurts my lungs. Anyone know anything about this? I bought one of those miller respirators that go under your helmet and the fits not that great and i do have a beard. when i do the "fit test" im good but i cold still taste smell that nastiness.

I'm a tig guy but I'll chime in here in the interests of your health. Flux core gives off some of the most toxic and carcinogenic chemical fumes known to man that hasn't been weaponized. It was developed by those interested in productivity gains without regard for the operator. In my own opinion it should be banned from use.
The minimum protection you should be using is forced air ventilation into your hood if you must use this process. If you are smelling the fumes, you are already dying. I don't think any form of facial filter is good enough against these toxins.
Others will chime in here in defense of fc, but the best advise I can give you is don't do it!

AKweldshop · Wed Jan 07, 2015 5:35 pm

AKweldshop wrote:I wish I could link you a good duelshield video to watch, but there is none....

Huh....

I'm wrong.
Miller happens to have some excellent duelshield, um, "fcaw-g",

videos.
Good arc shots.

1f,
https://www.youtube.com/watch?v=e5xslgQ6FLY
2f,
https://www.youtube.com/watch?v=Li_pAMrUWSw
3f,
https://www.youtube.com/watch?v=lKAJPyFOeVc
4f,
https://www.youtube.com/watch?v=WU4RSGn3qt4

Boomer63 · Thu Jan 08, 2015 2:26 pm

You can get undercut on the top plate from a bad gun angle, and by NOT holding the puddle long enough. Rushing or skipping away from the top plate will leave the undercut. If your weldments look 'arrow shaped' then you are rushing. Slow down. Try it, anyway!

AKweldshop · Wed Jan 14, 2015 3:09 am

First pass on a 3g.

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bigworm40 · Wed Jan 14, 2015 5:38 am

Hey guys sorry it has taken me so long to reply to all of you but i have taken it all in. Those videos are great thanks for all of your input. I ran some tests the other day and below are some of my results. in this picture the left leg was chamfered the right leg was not.

Material was all mild steel .625
Wire Lincoln ultracore gas shielded .045
gas 75/25
settings were
23/275 and 23.5 and 300

bigworm40 · Mon Jan 19, 2015 9:00 pm

So everything I have been practicing for is finally getting close. Over the last month our machinist and I have been drilling and preparing parts so once we start assembling we wont have to stop, and the time is near. For this weldment all the material will be A572 grade 50 at 1" thick. I'm using a Miller 252 with Lincoln UltraCore 71A85 Fluxcore and 75/25 gas. I know because of the size of everything I will have to do some 3g but will do everything I can to try and stay away from overhead. Its going to be a mix of tee joint, butt joint's and lap joint's. Any advice as far as chamfering? should I? If so how much, what degree? We have prints for everything but theres no weld specs!! Any way guys, you have been a great help so far thanks for everything you have taught me already.