Wire Feed Arc Welder

Welding Guidelines (Continued)

WIRE SPEED

 

After completing the weld, wait for the

 

 

 

 

 

 

 

 

The wire speed is controlled by the knob

 

welded sections to cool. A protective

 

 

 

 

 

 

 

 

on the front panel. The speed needs to

 

coating called slag now covers the weld

 

 

 

 

 

 

 

 

be “tuned” to the rate at which the wire

 

bead which prevents contaminants in

 

 

 

 

 

 

 

 

is being melted in the arc. Tuning is one

 

the air from reacting with the molten

 

 

 

 

 

 

 

 

of the most critical functions of wire feed

 

metal. Once the weld cools to the point

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

welding. Tuning should be performed on

 

that it is no longer glowing red, the

 

 

 

 

 

 

 

 

a scrap piece of metal the same type and

 

slag can be removed. Removal is done

 

 

 

 

 

 

 

 

thickness as that to be welded. Begin

 

with a chipping hammer. Lightly tap

 

 

 

 

 

 

 

 

welding with one hand “dragging” the

 

the slag with the hammer and break it

 

 

 

 

 

 

 

 

torch nozzle across the scrap piece while

 

loose from the weld bead. The final

 

 

 

 

 

 

 

 

adjusting the wire speed with the other

 

 

 

 

 

 

 

 

 

 

clean-up is done with a wire brush.

 

 

 

 

 

 

 

 

hand. Too slow of speed will cause

 

 

 

 

 

 

 

 

 

 

When making multiple weld passes,

 

 

 

 

 

 

 

 

sputtering and the wire will burn up into

 

 

 

 

 

 

 

 

 

 

remove the slag before each pass.

 

 

 

 

 

 

 

 

the contact tip. Too fast a speed will also

 

 

 

 

 

 

 

 

 

 

WELDING POSITIONS

 

 

 

 

 

 

 

 

cause a sputtering sound and the wire

 

 

Figure 9 - Multiple Weld Passes

 

Four basic welding positions can be used;

 

will push into the plate before melting. A

 

 

 

 

 

 

 

 

 

 

 

ALUMINUM WELDING

smooth buzzing sound indicates the wire

 

flat, horizontal, vertical, and overhead.

 

speed is properly tuned. Repeat the

 

Welding in the flat position is easier than

 

Any aluminum surface to be welded,

tuning procedure each time there is a

 

any of the others because welding speed

 

must be cleaned thoroughly with a

change in heat setting, wire diameter or

 

can be increased, the molten metal has less

 

stainless steel brush to eliminate any

type, or work piece material type or

 

tendency to run, better penetration can be

 

oxidation on the weld and grounding

thickness. For Aluminum, wire speed is

 

achieved, and the work is less fatiguing.

 

surface. 100% Argon shielding gas

typically set higher (7-9 speed range).

 

Welding is performed with the wire at a

 

must be used when welding aluminum.

 

 

If 100% Argon is not used, metal

TRAVEL SPEED

 

45º travel angle and 45º work angle.

 

 

 

penetration is unlikely. A PTFE wire liner,

The travel speed is the rate at which the

 

Other positions require different

 

 

 

smooth-groove drive roller and

torch is moved across the weld area.

 

techniques such as a weaving pass,

 

 

 

aluminum contact tips are

Factors such as diameter and type of weld

 

circular pass, and jogging. A higher skill

 

 

 

recommended when welding

wire, amperage, position, and work piece

 

level is required to complete these welds.

 

 

 

aluminum. Campbell Hausfeld offers

material thickness all affect the speed of

 

Overhead welding is the least desirable

 

these parts in Kit WT2531. Call 1-800-

travel necessary for completing a good

 

position as it is the most difficult and

 

746-5641 to order.

weld (See Figure 7). When the speed is

 

dangerous. Heat setting and wire selection

 

PUSH VS PULL TECHNIQUE

too fast, the bead is narrow and bead

 

 

 

will vary depending upon the position.

 

The type and thickness of the work piece

ripples are pointed as shown. When the

 

 

 

All work should be performed in the

 

dictates which way to point the torch

speed is too slow, the weld metal piles up

 

 

 

 

nozzle. For thin materials (18 gauge and

 

flat position if possible. For specific

 

and the bead is high and wide. For

 

 

 

 

smaller) and all aluminum, the nozzle

 

applications, consult an arc welding

 

Aluminum, travel speed is typically faster.

 

 

should point out in front of the weld

 

technical manual.

 

ELECTRODE EXTENSION

 

 

puddle and push the puddle across the

 

WELD PASSES

 

Electrode extension (or electrode stick-

 

 

workpiece. For thicker steel, the nozzle

out) is the distance between the end of

 

Sometimes more than one pass is necessary

 

should point into the puddle to increase

 

to fill the joint. The root pass is first,

 

weld penetration. This is called backhand

the contact tip and and the end of the

 

 

 

followed by filler passes and the cover pass.

 

or pull technique (See Figure 10).

welding wire. The recommended

 

 

 

If the pieces are thick, it may be necessary

 

 

 

 

 

 

 

 

electrode extension is from 1/4 to 1/2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to bevel the edges that are joined at a 60º

 

 

 

 

 

 

 

 

in (6 to 13 mm). If the electrode

 

 

 

 

 

 

 

 

 

 

angle. Remember to remove the slag

 

 

 

 

 

 

 

 

extension is too long, welding current

 

 

 

 

 

 

 

 

 

 

before each pass for the FCAW process.

 

 

 

 

 

 

 

 

will be reduced and the bead will be

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

high and narrow with less penetration.

 

Cover

 

 

 

 

 

 

 

 

SLAG REMOVAL

 

Filler

 

 

 

 

 

PULL

(FLUX-CORED WIRE ONLY)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Root

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Wear ANSI approved safety

 

 

 

 

 

 

 

 

 

 

 

glasses (ANSI Standard Z87.1)

 

 

 

 

 

 

 

 

 

 

 

and protective clothing when

 

 

 

 

Figure 10

 

 

 

PUSH

removing slag. Hot, flying

 

 

 

 

 

 

 

 

 

Figure 8 - Weld Passes

 

 

 

 

 

 

 

debris can cause personal injury to

 

 

 

 

 

 

 

 

 

anyone in the area.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

www.chpower.com

 

 

 

 

 

 

 

 

 

 

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