Welding Guidelines

General

The WF2150 and WF2154 can utilize the Flux Cored Arc Welding (FCAW) process. The WG2160 and WG2164 can utilize the Flux Cored Arc Welding (FCAW) process or the Gas Metal Arc Welding (GMAW) process. The weld must be protected (shielded) from contaminants in the air while it is molten. The FCAW process uses a tubular wire with a flux material inside. The flux creates a shielding gas when melted. The GMAW process uses inert gas to shield the weld while molten.

When current is produced by a transformer (welding machine) and flows through the circuit to the weld wire, an arc is formed between the end of the weld wire and the work piece. This arc melts the wire and the work piece. The melted metal of the weld wire flows into the molten crater and forms a bond with the work piece as shown (Figure 5).

Models WF2150, WF2154,

WG2160 and WG2164

Base

Metal

Normal Heat,

Travel

Wire Speed,

Speed

Travel Speed

Too Fast

Heat Too Low

Travel Speed

Heat Too High

Too Slow

Wire Speed Too Slow

 

Wire Speed

Too Fast

Figure 7 - Weld Appearance

Nozzle

Contact Tip

 

Shielding Gas

Flux

Slag

(Gasless only)

Weld

Wire

Crater

Work Piece

Figure 5 - Weld Components

Arc Welding Basics

Six basic techniques affect weld quality. These are: wire selection, heat setting, weld angle, wire speed, travel speed, and electrode extension. An understanding of these techniques is necessary for effective welds.

5º - 45º

WORK ANGLE

5º - 45º

TRAVEL ANGLE

Figure 6 - Weld Angle

HEAT SETTING

The correct heat involves the adjustment of the welding machine to the required setting. Heat or voltage is regulated by a switch on the welder. The heat setting used depends on the size (diameter) and type of wire, position of the weld, and the thickness of the work piece. Consult specifications listed on the welder. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 7.

WIRE TYPE AND SIZE

The correct choice of wire type involves a variety of factors, such as welding position, work piece material type, thickness, and condition of surface to be welded. The American Welding Society, AWS, has set up certain requirements for each type of wire.

FLUX-CORED WIRE

E - 7 0 T - GS

Weld strength, times 10,000 pounds per square inch

Welding positions (0 for flat or horizontal, 1 for any position)

Tubular flux-cored wire

Flux type

AWS E71T-GS or E71T-11 is recommended for this welder.

SOLID WIRE

ER - 70 S - 6

Weld strength, times 1,000 PSI

Solid wire

Wire composition

ER-70S6 is recommended for this welder.

WELD ANGLE

Weld angle is the angle at which the nozzle is held during the welding process. Using the correct angle ensures proper penetration and bead formation. As different welding positions and weld joints become necessary, nozzle angle becomes an increasingly important factor in obtaining a satisfactory weld. Weld angle involves two positions - travel angle and work angle.

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.

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