SMaintain a 3/4 in. (19 mm) tip-to-work distance, and have the contact tip recessed approximately 1/8 in. inside the nozzle if possible. See Figure 5-2.

Gas Nozzle

Contact Tip To Work

Contact Tube Recessed 1/8Distance 3/4 in. (19 mm) in. (3.2 mm) Inside The Nozzle

Figure 5-2. Contact Tube Position And Tip-To-Work Distance

SAvoid large weave beads on aluminum. If larger fillet welds are needed, multiple pass straight beads will provide better appearance and have less chance of cold lapping, burn through, and other weld defects.

SIt will be necessary to increase torch travel speed as the base material becomes heated during the welding process.

SThe skill level of the operator, joint types, fit up, and positions, as well as the welding power supply will all have a great influence on the weldability of the aluminum and your success.

C. Common Problems/Troubleshooting

SBurn through (melt through) caused by over heating the base material.

1.Increase travel speed. Make shorter welds.

2.Move around on part, spreading out the heat.

3.Use thicker material, change joint design or welding process to AC TIG.

4.Eliminate or reduce gaps.

SDirty welds.

1.Use push angle instead of drag technique.

2.Increase voltage to get into spray transfer.

3.Use proper base metal cleaning techniques (stainless steel brush).

4.Check for proper shielding gas and wire alloy type.

SWire burns back to contact tip during or at the end of the weld.

1.Maintain a 3/4 in. (19 mm) tip-to-work distance.

2.Check to make sure the contact tip size, drive rolls and gun liner match the wire diameter that you are using. (Sometimes an oversized tip can be used. The ID should only be one size larger than the wire diameter.)

SWire “bird nests” (piles up) in front of inlet guide on gun.

1.Check and adjust drive roll tension.

2.Check to make sure drive rolls match wire diameter.

3.Replace contact tip if fouled or plugged.(Sometimes an oversized tip can be used. The ID should only be one size larger than the wire diameter.)

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Hobart Welding Products DP 3035-20 manual Contact Tube Position And Tip-To-Work Distance, Common Problems/Troubleshooting
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DP 3035-10, DP 3035-20 specifications

Hobart Welding Products has established a reputation for manufacturing high-quality welding equipment, and their DP 3035-20 and DP 3035-10 models are prime examples of their innovative approach to welding technology. Designed to cater to a variety of welding needs, these products are engineered to enhance performance and provide durability in various industrial applications.

One of the main features of the Hobart DP 3035-20 and DP 3035-10 is their versatility. Both models are suitable for multiple welding processes, including MIG, TIG, and stick welding. This adaptability makes them ideal for fabricators, metalworkers, and DIY enthusiasts who require a reliable machine that can handle different types of materials and welding techniques. The machines are designed to work seamlessly with a range of metals, including steel, aluminum, and stainless steel, ensuring comprehensive usability across various projects.

Another remarkable aspect of these models is their advanced technology. Hobart incorporates cutting-edge inverter technology in both the DP 3035-20 and DP 3035-10, enabling these machines to deliver precise and consistent power output. This technology improves energy efficiency, reduces the overall weight of the welder, and enhances portability, making it easier for users to transport their equipment to job sites. Users can expect stable arc performance even at low amperage settings, further expanding their welding capabilities.

The user-friendly interface is another characteristic that sets the Hobart DP 3035 series apart. With clearly marked controls and a digital display, users can easily adjust settings for output and wire feed speed, facilitating an intuitive welding experience. Additionally, the process of switching between different welding modes is streamlined, allowing users to focus on their work without the hassle of complicated setups.

Durability is a priority for Hobart, and these welders are built to withstand the rigors of daily use. Featuring robust construction and high-grade components, the DP 3035-20 and DP 3035-10 are designed to provide long-lasting performance. They also come with built-in safety features such as thermal overload protection, ensuring reliable operation even under demanding conditions.

In conclusion, the Hobart Welding Products DP 3035-20 and DP 3035-10 models exemplify excellence in welding technology. With their versatile applications, advanced inverter technology, user-friendly design, and durable construction, these welders are well-equipped to meet the demands of modern welding tasks. Whether you are a professional tradesperson or a passionate hobbyist, these machines offer the reliability and performance that you need to achieve your welding goals.
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