Wire Feed Arc Welder
Welding Guidelines (Continued)
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 hori- zontal, 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.
5º - 45º
WORK ANGLE
5º - 45º
TRAVEL ANGLE
Figure 9 - Weld Angle
WIRE SPEED
The wire speed is controlled by the knob on the front panel. The speed needs to be “tuned” to the rate at which the wire is being melted in the arc. Tuning is one of the most critical functions in wire feed welding. Tuning should be performed on a scrap piece of metal the same type and thickness as that to be welded. Begin welding with one hand “dragging” the gun nozzle across the scrap piece while adjusting the wire speed with the other hand. Too slow of speed will cause sputtering and the wire will burn up into the contact tip. Too fast a speed will also cause a sputtering sound and the wire will push into the plate before melting. A smooth buzzing sound indicates the wire speed is properly tuned. For aluminum, wire speed is typically set higher (7 - 9 speed range).
NOTE: Repeat the tuning procedure each time there is a change in heat setting, wire diameter or type, or work piece material type or thickness.
TRAVEL SPEED
The travel speed is the rate at which the torch is moved across the weld area. Factors such as diameter and type of weld wire, amperage, position, and work piece material thickness all affect
the speed of travel necessary for completing a good weld (See Fig. 10). When the speed is too fast, the bead is narrow and bead ripples are pointed as shown. When the speed is too slow, the weld metal piles up and the bead is high and wide. For aluminum, travel speed is typically faster.
SLAG REMOVAL (FLUX-CORE WIRE ONLY)
Wear ANSI approved safety
glasses (ANSI Standard Z87.1) and protective clothing when removing slag. Hot, flying debris can cause personal injury to anyone in the area.
After completing the weld, wait for the welded sections to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed. Removal is done with a chipping hammer. Lightly tap the slag with the hammer and break it loose from the weld bead. The final
NOTE: When making multiple weld passes, remove the slag before each pass.
Base Metal
Normal Heat, Wire Speed, Travel Speed
Heat Too Low
Heat Too High
Figure 10 - Weld Appearance
Travel Speed Too Fast
Travel Speed Too Slow
Wire Speed Too Slow
Wire Speed Too Fast
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