Welding, Tips and Tricks ?

[Scuba]

Well since ive been getting so much advice in my project threads I figured I would just start a thread where I can post pictures of my welding so you guys can tell me what I'm doing wrong and what I'm doing right.

My welder is a 110V Lincoln running .30 Flux wire.

Today I had the welder out for some work on the bob job and found some scrap to weld together..

1st (IMO the best of these 3)
http://i11.photobucket.com/albums/a168/Sycosurfer150/DSCN1259.jpg

2nd ( I think I went a little slow)
http://i11.photobucket.com/albums/a168/Sycosurfer150/DSCN1260.jpg

3rd ( I think I varried the speed too much ??)
http://i11.photobucket.com/albums/a168/Sycosurfer150/DSCN1261.jpg

Tell me what you think :)

[Seanz0rz]

look ok. for me, strength > looks. unfortunatly pretty welds are usually strong too. haha.

are you welding with flux core? get rid of it! save up your allowance and get a tank of shielding gas. makes all the difference in the world!

practice, practice, practice!!! my fav welding method is to weld like (\(\(\(\(\( go up with a inward curve, curve it back down a little farther forward, curve it up a little further forward, etc, etc.

scour youtube for how to videos, search google for tips and tricks, go pick up some books a the store or library, etc. just learn everything you can, and practice makes perfect! good thing is you arent afraid to just jump in and do stuff. problems arise when you dont know enough to do it right! (but you seem to do ok)

[Seanz0rz]

oh also, alot of it is in your metal setup. allowing the proper gap between pieces for a butt weld, doing a tjoint properly, etc. this is stuff you will have to read up on!

[Scuba]

See thats the thing sean, This flux can run hotter and weld thicker stuff then the gas, Or so says the guide on the inside of my machine...

And since its only a 110 im ok with the flux.

If/When I ever upgrade to 220 I will for sure get a gas setup, but right now it just doesnt seem worth it..

Thanks for the advice..

[Robinhood4x4]

Cut it and see how good your penetration is.

[4x4mike]

X2. Try to break it and cut it open to check your penetration. I've got a 110 flux core and it's hard to make it look pretty. Just make sure you take your time and be consistent. With enough practice you'll start to get the hang of it and your welds will be more consistent.

I've got 110 flux core because I don't weld enough to warrant an expensive machine and the space. Most of the time it's just something here and there and it's been great. If I needed something big done I know enough to know that I don't have enough experience and that I'll take it to someone.

What wire are you using? I modded my welding machine to accept the 10 pound spools and I run the Lincoln innershield wire. It lasts much longer and is cheaper than the 2 pound spools. The Innershield is also much better than anything else that I've used.

[AxleIke]

Its best to bevel the edges before welding, and leave just a slight (1/16) gap when welding thicker material.

[corax]

oh also, alot of it is in your metal setup.

I know it's been said before, but only weld bare metal. It's hard to tell in your pics, but when you get metal it'll have a dull grey sheen to it (forget what it's called, scale?). Wire wheel/ flap disc the dull grey off till it's shiny ~1/2" on both sides of where you plan to lay a bead, then you're ready to weld.

BTW, there's almost no such thing as too slow when welding (unless you start building up huge mounds of metal, warp or burn through . . . actually, I guess there is too slow :)) - the biggest mistake most people make is to rush the job, which means colder welds and less penetration. The bead should sink into the metal without any signicant "rise" on the very edge of the weld. The first weld does look best, but it's hard to tell from the camera angle

[2ndGen]

first, dude, breath through your nose, don't get too excited when you pick up that mig gun. learn how to be patient, tack up the work piece, hold your gun, without pulling the trigger, just go through the whole bead, try to create some mussle memory.

when i was in trainning, we had a digital hydraulic press(not the hand pump one), every thing passed visual inspection we put it on there. i keep a few test piece in my garage just for the memories.

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0385.jpg

we use 3/8" mild steel plates, bevelled with 1/8" gap( called V-groove). this is a piece welded with .035 wire vertical up, no backing.

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0412.jpg

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0413.jpg

this is the backside

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0415.jpg

they all should be look like that before we can grind it down to a flush, cut in to strips then press test.

some are good, you can't even tell it's welded from two pieces.

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0386.jpg
http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0389.jpg

some are shat,

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0387.jpg

look, good looking weld can break, ugly welds can hold for ever, just noramlly a good looking weld would have better chance to hold, much better.

wehn you set up your work piece, make sure they have enough meat for the bead to grab. when you weld, metal melts and it has to have somewhere to go. start with a tee-joint as it's the easiest to pick up. i just did one with 3/16" plates. you need to have both the toe and heel of the bead bite into the metal. remember the word "FUSED" together.

http://i638.photobucket.com/albums/uu105/nwstindy/IMG_0409.jpg

have fun

[freejake3]

good tips for one and all. thanks for that. here's a good site with some very useful info:

http://www.offroadfabnet.com/

[Bob98SR5]

you welded on dirty metal, thats your first error. do this: with two pieces, weld down the middle to join the two pieces. but on the top half, grind down both sides. so weld the bottom dirty half first. then do the top. you will see and hear the difference.

second, practice like nobody's business on the same gauge metal. practice adjusting the settings and document what those settings are that worked for you.

third: after welding, go back to the internets and read up on welding techniques. keep doing all three and you will have good welds in no time

www.metalmeet.com is one of my favorite online forums. they are super cool there too

[Scuba]

Thank you all for the advice, You Guys are awesome !!

Should have some time tomorrow to get out in the garage. :clap:




:bling:

[Scuba]

Haven't updated this thread in a while.
I've had some practice since this was started, not much but im getting somewhat better..

Im about to start on a rear bumper, So I broke out the brand new chop saw and cut a 45 and welded it back together to see what happens.

http://i11.photobucket.com/albums/a168/Sycosurfer150/DSCN2047.jpg

http://i11.photobucket.com/albums/a168/Sycosurfer150/DSCN2048.jpg

http://i11.photobucket.com/albums/a168/Sycosurfer150/DSCN2050.jpg

Still running flux..

[Seanz0rz]

please go get yourself a tank of welding gas...

[CJM]

Now ya have to admit ya'll have seen much worse. For a 110v machine it aint that bad. Some grinding down would make a bit prettier tho and the shielding gas would help alot.

Try stick welding and get back to me, I find it extremely difficult

[Seanz0rz]

yeah ive seen much worse welds, and you are getting much better steve. just go get some welding gas, it makes all the difference! its much less distracting to weld with a shielding gas than flux core that kind of pops and crackles constantly.

[corax]

Steve, those are looking pretty good :thumbup:

Once you start welding with gas you'll never want to run flux core again - much less clean-up and prettier welds. I can lay a decently good looking bead of flux core, and it's convenient for quick/cheap/dirty welds, but with gas I can make them downright purdy (even on sheet metal which is nearly impossible with flux core)

[BruceTS]

this is what shielding looks like.... 75% argon/ 25% CO2. .035 wire 110v setting 3


http://img268.imagevenue.com/loc16/th_36306_D08193_122_16lo.jpg (http://img268.imagevenue.com/img.php?image=36306_D08193_122_16lo.jpg)

notice the lack of splatter everywhere....

[CJM]

Watching xtreme 4x4 this morning on spike and they explained some ways to weld and what welds are stronger.

1. Weld then go back method. You weld a bit then go back over the weld to ensure penetration. According to them it causes poor penetration and you muck up the weld cause the shielding gas doesnt work properly.

2. Weld in circle method. Same as the above with the gas and such not giving enough penetration. TBH I still feel this weld is plenty strong.

3. C method. They said this was the best weld, doesnt cause gas issues and excellent penetration..

The more ya know..