Campbell Hausfeld GR3000 Welding Guidelines (Continued)

Operating Instructions

Welding Guidelines (Continued)

Arc welding basics

Four basic techniques affect weld quality. These are: amperage setting, weld angle, arc length, and travel speed. Proper use of these techniques is necessary for good weld quality.

Amperage setting

The correct amperage involves the adjustment of the welding machine to the required amp setting. This is regulated by a knob on the welder. The amperage required depends on the size (diameter) of electrode used and the thickness of the work piece. Consult specifications listed on the welder. Excessive amps burn through light metals and the weld bead is flat and porous (See Figure 4). The bead appears high and irregular if the amperage is too low.

Weld angle

Weld angle is the angle at which the electrode is held during the welding process. Using the correct angle ensures proper penetration and bead formation. Electrode angle involves two positions - travel angle and work angle (See Figure 5).

Travel angle is the angle in the line of welding and may vary from 5º to 45º from the vertical, depending on welding conditions.

Work angle is the angle from horizontal, measured at right angles to the line of welding.

For most applications, a 45º travel angle and 45º work angle is sufficient. For specific applications, consult an arc welding handbook.

NOTE: Right handed welders should weld from left to right. Left handed welders should weld from right to left. The electrode should always point into the weld puddle as shown.

Arc length

Arc length is the distance from the work piece to the tip of the electrode, the distance which the arc must travel. A proper arc length is essential to generate the heat needed for welding (See Figure 4). An arc that is too long produces an unstable arc, reduces penetration, increases spatter, and causes flat and wide beads. Too short an arc does not create enough heat to melt the work piece, the electrode has a tendency to stick, penetration will be poor, and uneven beads with irregular ripples result. A proper arc should be no longer than the diameter of the rod. The sound of a proper arc is a steady, crisp sizzle, similar to bacon frying.