Wire Feed Arc Welder
Welding Guidelines (Continued)
WIRE SPEED |
| After completing the weld, wait for the |
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The wire speed is controlled by the knob |
| welded sections to cool. A protective |
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on the front panel. The speed needs to |
| coating called slag now covers the weld |
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be “tuned” to the rate at which the wire |
| bead which prevents contaminants in |
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is being melted in the arc. Tuning is one |
| the air from reacting with the molten |
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of the most critical functions of wire feed |
| metal. Once the weld cools to the point |
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welding. Tuning should be performed on |
| that it is no longer glowing red, the |
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a scrap piece of metal the same type and |
| slag can be removed. Removal is done |
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thickness as that to be welded. Begin |
| with a chipping hammer. Lightly tap |
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welding with one hand “dragging” the |
| the slag with the hammer and break it |
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torch nozzle across the scrap piece while |
| loose from the weld bead. The final |
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adjusting the wire speed with the other |
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hand. Too slow of speed will cause |
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| When making multiple weld passes, |
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sputtering and the wire will burn up into |
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| remove the slag before each pass. |
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the contact tip. Too fast a speed will also |
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| WELDING POSITIONS |
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cause a sputtering sound and the wire |
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| Figure 9 - Multiple Weld Passes | |||||||||||
| Four basic welding positions can be used; |
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will push into the plate before melting. A |
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| ALUMINUM WELDING | ||||||||||||
smooth buzzing sound indicates the wire |
| flat, horizontal, vertical, and overhead. |
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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 |
| Welding is performed with the wire at a |
| must be used when welding aluminum. | ||||||||||
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| If 100% Argon is not used, metal | ||||||||||||
TRAVEL SPEED |
| 45º travel angle and 45º work angle. |
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| penetration is unlikely. A PTFE wire liner, | ||||||||||||
The travel speed is the rate at which the |
| Other positions require different |
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torch is moved across the weld area. |
| techniques such as a weaving pass, |
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| aluminum contact tips are | ||||||||||||
Factors such as diameter and type of weld |
| circular pass, and jogging. A higher skill |
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| recommended when welding | ||||||||||||
wire, amperage, position, and work piece |
| level is required to complete these welds. |
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| aluminum. Campbell Hausfeld offers | ||||||||||||
material thickness all affect the speed of |
| Overhead welding is the least desirable |
| these parts in Kit WT2531. Call | ||||||||||
travel necessary for completing a good |
| position as it is the most difficult and |
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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 |
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| will vary depending upon the position. |
| The type and thickness of the work piece | |||||||||||
ripples are pointed as shown. When the |
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| All work should be performed in the |
| dictates which way to point the torch | |||||||||||
speed is too slow, the weld metal piles up |
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| nozzle. For thin materials (18 gauge and | ||||||||||||
| flat position if possible. For specific |
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and the bead is high and wide. For |
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| smaller) and all aluminum, the nozzle | ||||||||||||
| applications, consult an arc welding |
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Aluminum, travel speed is typically faster. |
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| should point out in front of the weld | |||||||||||
| technical manual. |
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ELECTRODE EXTENSION |
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| puddle and push the puddle across the | |||||||||||
| WELD PASSES |
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Electrode extension (or electrode stick- |
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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 |
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| followed by filler passes and the cover pass. |
| or pull technique (See Figure 10). | |||||||||||
welding wire. The recommended |
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| If the pieces are thick, it may be necessary |
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electrode extension is from 1/4 to 1/2 |
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| to bevel the edges that are joined at a 60º |
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in (6 to 13 mm). If the electrode |
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| angle. Remember to remove the slag |
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extension is too long, welding current |
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| before each pass for the FCAW process. |
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will be reduced and the bead will be |
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high and narrow with less penetration. |
| Cover |
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SLAG REMOVAL |
| Filler |
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| PULL | ||||||
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| Root |
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Wear ANSI approved safety |
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glasses (ANSI Standard Z87.1) |
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and protective clothing when |
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| Figure 10 |
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| PUSH | |||||
removing slag. Hot, flying |
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| Figure 8 - Weld Passes |
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debris can cause personal injury to |
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anyone in the area. |
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www.chpower.com |
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