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[Music]

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[Music]

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me

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hi my name is Steve Boyle and I'm a

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welder wire feed in one form or another

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has become the standard of the welding

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industry and with the development of

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less expensive welding machines it's not

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common in all types of repair shops on

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farms and ranches and even in Home shops

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there are quite a few different manual

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and automatic wire feed processes we'll

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be looking at gas metal arc welding

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which is often referred to as Meg this

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process uses a continuous solid wire
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along with an externally furnished

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shielding gas that protects the molten

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weld metal from coming in contact with

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the surrounding air the weld puddle and

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weld buildup are very controllable and

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the finished weld bead is virtually slag

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free this process was first used in

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industry around the mid 1940s to speed

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up the production welding of heavy

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aluminum plate a solid metal wire was

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used with an inert shielding gas either

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argon or helium this was referred to as

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Meg for metal inert gas the

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characteristics of the inert shielding

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gases did not work well for welding on

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carbon steel and this process did not

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become widespread until new wires were

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developed and used with either carbon

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dioxide or carbon dioxide argon blend

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because carbon dioxide is not an inert

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gas the term MIG is technically

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incorrect everybody still uses it MIG

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welding is a very familiar term but the

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American Welding Society has designated

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this as the gas metal arc welding

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process to include all types of solid

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wire and shielding gases now wire feed

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welding does have the reputation for

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being real easy it might be a little

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more accurate to say that it's easy to

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get started in any type of electric arc

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welding the distance at the arc travels

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between the electrode and the metal

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called the arc gap is extremely

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important with wire feed when the

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voltage and wire speed are set correctly

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the welding machine automatically

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maintains a constant arc gap even with

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slight variations in the position of

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the wire feed gun you can make a well

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the very first time you pull the trigger

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but there's more to joining metal than

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just squirting weld this is considered a

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manual wire feed process even though the
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welding equipment does maintain the arc

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feed the wire and supply the shielding

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gas the welder still needs to control

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the position of the wire feed gun the

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direction of the weld and the speed of

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travel

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there's also metal preparation and joint

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fit up some of this is technical

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information it some deals with welder

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skill well there isn't anything that's

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especially difficult or complex the more

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you learn both about the welding part of

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it and the technical aspects the more

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efficient and effective you'll be

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whether you're headed into the welding
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industry or out into your garage

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[Music]

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a typical wire feed welding setup

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consists of a power source wire feed

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unit the gun assembly a ground

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connection and a high-pressure bottle

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with a flow meter this is considered an

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all-in-one machine the power source and

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wire feed unit are combined in industry

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where more powerful equipment is used

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the wire feed unit may be separate from

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the power source regardless of the type

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size or brand name these machines all do

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the same thing provide current feed wire

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and regulate the gas flow so basically

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they all have the same parts wire feed

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welding machines use a constant voltage

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direct current power source this

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particular machine uses a transformer

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rectifier to change alternating current

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from the wall outlet into direct current

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that's supplied to the welding wire with

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DC power the direction that the current

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flows called polarity is determined by

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how the leads are connected to the

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terminals Wehling wires are designed to

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run on a specific polarity and all the

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common wires for welding on carbon steel

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use direct current electrode positive

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with the lead to the welding wire which

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is the electrode attached to the

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positive terminal wire feed also uses a

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cv or constant voltage power source this

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is different from a stick rod welding

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machine which uses constant current

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while you're welding the voltage and

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amperage are always readjusting to keep

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the arc going in wire feed this mainly

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happens when the gun is held closer or

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further away from the metal a constant

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voltage power source tries to maintain

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the voltage with the amperage bearing to

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provide the current necessary to burn

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off the wire and maintain the arc cv
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power sources stabilized quickly

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allowing the drive rolls to feed the

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wire at a constant speed the whole wire

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feed unit itself is fairly simple

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there's a spindle to hold a roll of wire

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with a catch that's inserted into the

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back of the spool the spring-loaded nut

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at the end of the spindle is tightened

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just enough so the spool stops when a

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driver will stop and it doesn't continue

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from momentum the wire should come off

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relatively straight through a guide that

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keeps it centered in the grooves on the

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drive rolls and

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to a steel liner that's inside the gun
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assembly dry rolls are designed for

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specific wire sizes that should be

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indicated on the side of the roll

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when you close the drive rolls just

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tighten them enough to keep the wire

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from slipping

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besides the steel liner the gun assembly

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also contains a hose for the shielding

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gas a welding lead supplying current to

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the contact tip where the welding wire

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is energized and control wires attached

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to the trigger at the end of the gun you

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have an insulator and adaptor the

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contact tip and the nozzle contact tips

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come in different sizes to match the

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wire diameter and also in different

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lengths for gas metal arc welding the

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contact tip should be nearly flush with

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the end of the nozzle when you're

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installing a new roll of wire after it's

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inserted into the liner and the drive

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rolls are closed lower the hood turn the

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machine on and straighten the lead up a

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little then pull the trigger there is a

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very close tolerance between the wire

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diameter and the opening in the contact

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tip it's a good idea to have the nozzle

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and the tip removed until the wires all

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the way through last is a shilling gas

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bottle and flow meter this is a high

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pressure bottle and can be filled over

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2,000 pounds per square inch you need to

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protect the cylinder valve from getting

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damaged when the bottle is in use it

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needs to be chained up securely and when

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it's not in use or you intend to move

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the bottle always use the protective

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valve cover even if the bottle is empty

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the flow meter regulates the amount of

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gas flow measured in cubic feet per hour

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several styles are available with the

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high pressure gauge indicating the

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pressure inside the bottle and the other

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gauge used to adjust the flow of gas to
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open the bottle get the habit of

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standing back behind the valve just in

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case something does come apart crack the

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valve slowly then open it all the way

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high pressure valves have two seats one

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to close the bottle and the other to

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seal the valve stem when the bottle is

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open so open the valve all the way

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regardless of the style of flow meter

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you're using you get a more accurate

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adjustment with the gas flowing so pull

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the trigger on the gun ideally you want

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use the minimum amount of gas that it

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takes to cover the molten well usually

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around 20 cubic feet per hour
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excessive gas flow may have a cooling

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effect on the well pub and if there's

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not enough gas coverage or you lose the

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shielding gas for some reason gas

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pockets call porosity will form in the

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weld bead with the flow meter set snip

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off the excess wire and you're ready to

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do some welding this is industrial

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equipment and even the smaller welding

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machines are well built but part of wire

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feed Welling is keeping the wire feeding

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smoothly let's go back through and take

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a look at some of the things you need to

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pay attention to while you're welding

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little bits a hot metal called weld

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spatter fly out of the molten puddle

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regularly check the nozzle and clean out

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any buildup of that weld spatter there

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are anti spatter products available

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either a dip or a spray these don't stop

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the spatter just help to keep it from

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sticking you want to make sure you don't

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have any weld spatter on the end of the

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contact tip too if that heats up it

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expands and pinches the wire causing it

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to feed erratically the wire can also

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burn back sticking at the tip this

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generally happens when you're starting

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the arc especially if you're in an

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awkward position or the metal isn't

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clean it's a good idea to keep a few

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extra contact tips on hand the nozzle

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will either push on or screw on but it

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needs to fit snugly if it loosens up you

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may have to replace the insulator it's

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clean and shiny as the wire looks it

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still causes dust from the shop to gum

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up the liner right where the wire goes

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in this can build up enough to stop the

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wire from feeding consistently

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installing a wiper with some cleaner

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seems to help keep everything operating

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smoothly it is extremely difficult to

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make a good well when the wire is not
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feeding correctly generally any problems

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will not be equipment failure but rather

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some kind of contamination either dirt

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buildup or weld spatter take the time to

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keep everything clean in a good working

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condition

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[Music]

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with the increased use of gas metal arc

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welding many filler wires and shielding

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gas blends have been developed keep in

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mind only in recent years with the

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introduction of smaller welding machines

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as this process become popular for

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general-purpose welding it was

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originally developed and is used
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extensively to increase the speed of

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industrial welding and you'll find that

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most of the gases and wires are used for

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high-speed production of the filler wire

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is available for welding on carbon steel

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the most commonly used is er 70 s6 all

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these wires have a seventy thousand

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pound per square inch tensile strength

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indicated by the 70 tensile strength is

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a force it takes to pull it apart the

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difference between the filler wires is

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the type and amount of chemicals that

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are added to the metal these are called

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the oxidizers and help clean surface

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oxides and gases from the molten weld

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leaving small slag deposits on the

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finished weld bead er 70 s6 contains

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higher amounts of silicon and manganese

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while it is a little more expensive it

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does produce quality welds in different

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welding situations the diameter of the

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filler wire is selected for the amount

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of the finished well required and the

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deposit rate o to 3 is often used with

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the smaller welding machines and o3o is

277
00:11:56,250 --> 00:11:58,950
generally used on gauge metals in the

278
00:11:58,950 --> 00:12:01,650
welding industry o 3 5 is considered

279
00:12:01,650 --> 00:12:04,530
most efficient for metals up to 3/16 of

280
00:12:04,530 --> 00:12:08,070
an inch on heavier metals o 4 5 will

281
00:12:08,070 --> 00:12:10,440
provide high filler metal deposit rates

282
00:12:10,440 --> 00:12:12,840
for general-purpose welding where

283
00:12:12,840 --> 00:12:14,700
varying amounts of weld deposit are

284
00:12:14,700 --> 00:12:16,590
required for different metal thicknesses

285
00:12:16,590 --> 00:12:19,610
the wire size is more of a compromise

286
00:12:19,610 --> 00:12:23,040
typically using a smaller wire like O 3

287
00:12:23,040 --> 00:12:25,800
5 and turning the welding machine up for

288
00:12:25,800 --> 00:12:27,720
thicker metals will give better results

289
00:12:27,720 --> 00:12:31,050
than using the larger o 4 5 and trying

290
00:12:31,050 --> 00:12:33,150
to turn the machine down running cold

291
00:12:33,150 --> 00:12:35,820
for the thinner gauge metals the

292
00:12:35,820 --> 00:12:37,410
shielding gas used for welding out

293
00:12:37,410 --> 00:12:39,630
carbon steel is generally a blend of

294
00:12:39,630 --> 00:12:42,250
carbon dioxide and argon

295
00:12:42,250 --> 00:12:44,650
the main job of the shielding gas is to
296
00:12:44,650 --> 00:12:46,630
cover the molten weld and keep it from

297
00:12:46,630 --> 00:12:48,700
coming in contact with oxygen and

298
00:12:48,700 --> 00:12:51,550
nitrogen in the surrounding air but

299
00:12:51,550 --> 00:12:53,140
these gases also affect the

300
00:12:53,140 --> 00:12:56,110
characteristics of the arc itself the

301
00:12:56,110 --> 00:12:58,540
arc creates a stream of hot electrically

302
00:12:58,540 --> 00:13:01,570
charged gases straight carbon dioxide

303
00:13:01,570 --> 00:13:03,820
does not transfer current well it

304
00:13:03,820 --> 00:13:07,000
requires a higher voltage a wide arc

305
00:13:07,000 --> 00:13:09,400
stream is formed with a lot of energy

306
00:13:09,400 --> 00:13:11,860
that breaks up surface oxide and allows

307
00:13:11,860 --> 00:13:14,860
good penetration and well fusion while

308
00:13:14,860 --> 00:13:17,170
all that arc energy does help to produce

309
00:13:17,170 --> 00:13:19,900
a strong well the problem with straight

310
00:13:19,900 --> 00:13:22,540
carbon dioxide is that it just isn't any
311
00:13:22,540 --> 00:13:25,480
fun to weld with the high voltage and

312
00:13:25,480 --> 00:13:27,640
arc energy causes the harsh arc that

313
00:13:27,640 --> 00:13:30,130
creates more weld splatter and agitates

314
00:13:30,130 --> 00:13:32,230
the weld puddle making it difficult to

315
00:13:32,230 --> 00:13:35,560
control pure argon on the other hand

316
00:13:35,560 --> 00:13:38,190
transfers current extremely well

317
00:13:38,190 --> 00:13:41,500
requiring less voltage argon produces a

318
00:13:41,500 --> 00:13:44,530
narrow dense arc stream with a secondary

319
00:13:44,530 --> 00:13:47,080
stream that has very little energy on

320
00:13:47,080 --> 00:13:49,510
carbon steel well it's made with pure

321
00:13:49,510 --> 00:13:52,030
argon would penetrate in the center but

322
00:13:52,030 --> 00:13:54,010
the filler metal would not fuse along

323
00:13:54,010 --> 00:13:56,500
the sides what they've done is mixed

324
00:13:56,500 --> 00:13:58,870
carbon dioxide with argon and varying

325
00:13:58,870 --> 00:14:01,420
amounts to provide sufficient arc energy

326
00:14:01,420 --> 00:14:04,900
at lower voltages the gas blend is

327
00:14:04,900 --> 00:14:07,120
chosen for the amount of this arc energy

328
00:14:07,120 --> 00:14:09,640
it provides and most of the argon rich

329
00:14:09,640 --> 00:14:11,890
gases are used with high voltage in

330
00:14:11,890 --> 00:14:14,770
production welding for some situations

331
00:14:14,770 --> 00:14:17,350
because the higher argon content does

332
00:14:17,350 --> 00:14:19,870
reduce the energy a little oxygen may be

333
00:14:19,870 --> 00:14:21,850
added just to kind of stir things up

334
00:14:21,850 --> 00:14:24,730
again for general purpose I'll position

335
00:14:24,730 --> 00:14:27,190
welding which uses lower voltage

336
00:14:27,190 --> 00:14:30,460
settings either co2 or more commonly a

337
00:14:30,460 --> 00:14:34,800
blend of 75% argon at 25 percent co2

338
00:14:34,800 --> 00:14:37,780
provides the arc energy necessary for

339
00:14:37,780 --> 00:14:39,950
good weld fusion

340
00:14:39,950 --> 00:14:46,820
[Music]

341
00:14:48,630 --> 00:14:51,730
with gas metal arc welding when you pull

342
00:14:51,730 --> 00:14:54,070
the trigger on the wire feed gun three

343
00:14:54,070 --> 00:14:57,040
things happen simultaneously circuits in

344
00:14:57,040 --> 00:14:58,990
the power source make current available

345
00:14:58,990 --> 00:15:01,750
to the wire a solenoid opens a valve

346
00:15:01,750 --> 00:15:04,000
allowing the shielding gas to flow and

347
00:15:04,000 --> 00:15:07,420
the drive rolls feed wire when the wire

348
00:15:07,420 --> 00:15:10,030
touches the metal the arcus started

349
00:15:10,030 --> 00:15:12,390
creating the molten weld puddle

350
00:15:12,390 --> 00:15:14,680
everything works together to provide a

351
00:15:14,680 --> 00:15:17,080
stable transfer of filler metal from the

352
00:15:17,080 --> 00:15:20,020
wire to the weld puddle one of the

353
00:15:20,020 --> 00:15:22,090
unique characteristics of wire feed

354
00:15:22,090 --> 00:15:24,610
Welling is that if you want more well
355
00:15:24,610 --> 00:15:26,800
deposit or more heat for better weld

356
00:15:26,800 --> 00:15:29,590
fusion you simply turn the Machine up

357
00:15:29,590 --> 00:15:32,650
each of these wires will operate over a

358
00:15:32,650 --> 00:15:34,990
wide range of voltage and wire speed

359
00:15:34,990 --> 00:15:37,630
settings throughout these ranges though

360
00:15:37,630 --> 00:15:39,790
the filler metal is transferred

361
00:15:39,790 --> 00:15:42,550
differently at the lower voltage range

362
00:15:42,550 --> 00:15:45,040
when the wire makes contact with a base

363
00:15:45,040 --> 00:15:47,710
metal current causes a tip of the wire

364
00:15:47,710 --> 00:15:50,460
to heat up until it pinches off and arcs

365
00:15:50,460 --> 00:15:53,650
the hot gas is surrounding the arc melt

366
00:15:53,650 --> 00:15:56,170
the filler and the base metal fusing

367
00:15:56,170 --> 00:15:59,260
them together the continuously fed wire

368
00:15:59,260 --> 00:16:01,600
then overcomes the heat of the arc and

369
00:16:01,600 --> 00:16:04,480
contacts the metal again heating it up
370
00:16:04,480 --> 00:16:08,710
pinching it off arcing and fusing this

371
00:16:08,710 --> 00:16:11,200
is called short circuit transfer and the

372
00:16:11,200 --> 00:16:14,140
cycle happens 50 to 200 times a second

373
00:16:14,140 --> 00:16:16,930
producing a distinctive sound and a weld

374
00:16:16,930 --> 00:16:19,900
puddle that's very easy to control this

375
00:16:19,900 --> 00:16:22,960
arc on our co-op allows the molten metal

376
00:16:22,960 --> 00:16:24,790
to cool enough so that welds can be made

377
00:16:24,790 --> 00:16:28,200
in all positions flat horizontal

378
00:16:28,200 --> 00:16:32,710
vertical and overhead short circuit

379
00:16:32,710 --> 00:16:34,480
transfer is considered to happen at

380
00:16:34,480 --> 00:16:37,960
settings up to 22 volts this voltage

381
00:16:37,960 --> 00:16:40,090
range and metal transfer is used for

382
00:16:40,090 --> 00:16:42,700
welding on thin gauge metals or to metal

383
00:16:42,700 --> 00:16:45,630
type projects and light structural in

384
00:16:45,630 --> 00:16:48,040
situations where better penetration or

385
00:16:48,040 --> 00:16:50,920
more well buildup is needed the voltage

386
00:16:50,920 --> 00:16:53,800
and wire speed can be increased at a

387
00:16:53,800 --> 00:16:56,710
certain point around 22 volts the wire

388
00:16:56,710 --> 00:16:59,020
can no longer overcome the heat of the

389
00:16:59,020 --> 00:17:00,820
arc and you have an open arm

390
00:17:00,820 --> 00:17:04,660
it's on all the time hot gases create a

391
00:17:04,660 --> 00:17:07,060
constant arc stream that melts the base

392
00:17:07,060 --> 00:17:11,020
metal with a carbon dioxide or 7525

393
00:17:11,020 --> 00:17:13,930
shielding gas the filler wire transfers

394
00:17:13,930 --> 00:17:16,210
across the arc stream of molten globs

395
00:17:16,210 --> 00:17:19,089
this is called globular transfer it

396
00:17:19,089 --> 00:17:21,579
produces deep penetration and good

397
00:17:21,579 --> 00:17:24,670
filler to base metal fusion because of

398
00:17:24,670 --> 00:17:26,710
the amount of heat and well deposit at

399
00:17:26,710 --> 00:17:28,930
these high settings the molten weld

400
00:17:28,930 --> 00:17:31,810
puddle is extremely fluid limiting

401
00:17:31,810 --> 00:17:34,090
globular transfer to the flat welding

402
00:17:34,090 --> 00:17:37,390
position or for horizontal Filat this

403
00:17:37,390 --> 00:17:40,030
will provide a strong weld at faster

404
00:17:40,030 --> 00:17:41,980
welding speeds but the arc stream

405
00:17:41,980 --> 00:17:45,820
produced by co2 or 7525 allows some of

406
00:17:45,820 --> 00:17:48,310
the globs to escape causing excessive

407
00:17:48,310 --> 00:17:51,640
weld spatter for projects requiring a

408
00:17:51,640 --> 00:17:54,040
limited number of welds this spatter can

409
00:17:54,040 --> 00:17:56,260
be dealt with but in production that's

410
00:17:56,260 --> 00:17:58,180
undesirable because of the time it takes

411
00:17:58,180 --> 00:18:00,730
to clean up here's where all those

412
00:18:00,730 --> 00:18:02,740
different shielding gases come into play

413
00:18:02,740 --> 00:18:06,220
by switching to an argon rich gas at the
414
00:18:06,220 --> 00:18:08,370
higher voltage range the dense

415
00:18:08,370 --> 00:18:10,690
concentrated arc stream causes the

416
00:18:10,690 --> 00:18:12,580
filler metal to break up into smaller

417
00:18:12,580 --> 00:18:16,090
pieces this is called spray transfer the

418
00:18:16,090 --> 00:18:18,580
small pieces are sprayed across the arc

419
00:18:18,580 --> 00:18:21,400
stream into the molten puddle this is

420
00:18:21,400 --> 00:18:23,830
the wire feed process typically used for

421
00:18:23,830 --> 00:18:26,200
the efficient high speed production

422
00:18:26,200 --> 00:18:28,360
welding that is up to 3/8 of an inch

423
00:18:28,360 --> 00:18:31,390
thick here again because of the amount

424
00:18:31,390 --> 00:18:34,270
of heat and weld metal spray transfer is

425
00:18:34,270 --> 00:18:36,400
generally used only when the weld can be

426
00:18:36,400 --> 00:18:39,820
positioned flat these methods of metal

427
00:18:39,820 --> 00:18:42,430
transfer throughout the wide voltage and

428
00:18:42,430 --> 00:18:44,770
wire speed range are what makes gas
429
00:18:44,770 --> 00:18:47,680
metal arc welding so versatile we've set

430
00:18:47,680 --> 00:18:49,690
this machine up with some oh three five

431
00:18:49,690 --> 00:18:53,680
er 70 s six filler wire and a 7525

432
00:18:53,680 --> 00:18:56,380
shielding gas for the all position short

433
00:18:56,380 --> 00:19:00,170
circuit transfer let's try some welding

434
00:19:00,170 --> 00:19:06,710
[Music]

435
00:19:08,830 --> 00:19:11,330
just like every other type of welding

436
00:19:11,330 --> 00:19:14,210
wire feed throws sparks which are little

437
00:19:14,210 --> 00:19:17,360
bits a hot metal cover yourself up or

438
00:19:17,360 --> 00:19:20,150
some good gloves a hat and always wear

439
00:19:20,150 --> 00:19:23,030
safety glasses besides hot metal sparks

440
00:19:23,030 --> 00:19:25,400
flying around impurities can pop off the

441
00:19:25,400 --> 00:19:27,200
surface of the metal when it's heating

442
00:19:27,200 --> 00:19:29,930
up or cooling make sure the lenses in

443
00:19:29,930 --> 00:19:32,390
your hood are clean industry recommends

444
00:19:32,390 --> 00:19:35,150
a number-10 shaded lens for the lower

445
00:19:35,150 --> 00:19:37,490
voltage ranges of short circuit welding

446
00:19:37,490 --> 00:19:40,040
I use in number 9 which is a little

447
00:19:40,040 --> 00:19:42,500
lighter this type of welding moves right

448
00:19:42,500 --> 00:19:45,020
along in many situations you need to be

449
00:19:45,020 --> 00:19:47,930
able to see where you're going use clear

450
00:19:47,930 --> 00:19:49,970
plastic lenses to protect the shaded

451
00:19:49,970 --> 00:19:52,070
lens and make sure everything is sealed

452
00:19:52,070 --> 00:19:54,020
so that there isn't any light linking

453
00:19:54,020 --> 00:19:57,350
around the edges inside the hood ideally

454
00:19:57,350 --> 00:19:59,090
the ground clamp should be attached

455
00:19:59,090 --> 00:20:01,250
directly to the metal you're welding on

456
00:20:01,250 --> 00:20:03,740
that's not always possible sometimes

457
00:20:03,740 --> 00:20:06,290
it's clamped to the work table but

458
00:20:06,290 --> 00:20:08,060
because of the relatively low voltage

459
00:20:08,060 --> 00:20:10,400
it's important to have a good clean

460
00:20:10,400 --> 00:20:13,040
ground if the wire sputters at the

461
00:20:13,040 --> 00:20:15,080
beginning or during the weld and the arc

462
00:20:15,080 --> 00:20:17,090
seems like it doesn't want to stay lit

463
00:20:17,090 --> 00:20:20,270
check the ground connection to start the

464
00:20:20,270 --> 00:20:22,730
weld trim the wire so the gun can be

465
00:20:22,730 --> 00:20:25,310
held close to the metal steady yourself

466
00:20:25,310 --> 00:20:27,860
by using both hands on the wire feed gun

467
00:20:27,860 --> 00:20:31,250
with one arm supported move your head in

468
00:20:31,250 --> 00:20:33,500
close to be able to see the molten weld

469
00:20:33,500 --> 00:20:35,900
puddle when you're comfortable either

470
00:20:35,900 --> 00:20:38,180
reach up and slide your hood down or you

471
00:20:38,180 --> 00:20:40,250
can adjust the knobs on the side to flip

472
00:20:40,250 --> 00:20:44,570
the hood down with a nod then pull the
473
00:20:44,570 --> 00:20:48,380
trigger the molten puddle is controlled

474
00:20:48,380 --> 00:20:50,300
by the distance of the gun is held from

475
00:20:50,300 --> 00:20:53,030
the metal where the arc hits the puddle

476
00:20:53,030 --> 00:20:56,240
the angle of the gun and the travel

477
00:20:56,240 --> 00:20:59,570
speed on the wire feed gun the contact

478
00:20:59,570 --> 00:21:01,640
tip should be nearly flush with the end

479
00:21:01,640 --> 00:21:03,890
of the nozzle the length of wire that

480
00:21:03,890 --> 00:21:06,590
sticks out from the contact tab called

481
00:21:06,590 --> 00:21:08,900
electrode extension or wire stick out

482
00:21:08,900 --> 00:21:11,060
will affect the amount of heat at the

483
00:21:11,060 --> 00:21:13,910
well constant voltage power sources

484
00:21:13,910 --> 00:21:16,550
maintain the arc gap and provide the

485
00:21:16,550 --> 00:21:19,690
amperage necessary to burn off the wire

486
00:21:19,690 --> 00:21:22,420
most welds the recommended wire stick

487
00:21:22,420 --> 00:21:24,640
out from the contact tip to the model is
488
00:21:24,640 --> 00:21:26,610
a quarter to three eighths of an inch

489
00:21:26,610 --> 00:21:29,110
longer electrode extensions allow the

490
00:21:29,110 --> 00:21:32,050
wire to preheat reducing the amperage

491
00:21:32,050 --> 00:21:34,540
necessary to burn it off and reducing

492
00:21:34,540 --> 00:21:37,180
the amount of heat at the well holding

493
00:21:37,180 --> 00:21:39,160
the gun closer which shortens the

494
00:21:39,160 --> 00:21:41,410
electrode extension increases the

495
00:21:41,410 --> 00:21:43,960
amperage and heat for better weld fusion

496
00:21:43,960 --> 00:21:46,450
the distance that the wire feed gun is

497
00:21:46,450 --> 00:21:48,670
held from the metal does give the welder

498
00:21:48,670 --> 00:21:51,400
a little more control of the heat for

499
00:21:51,400 --> 00:21:53,980
good hot starts hold the gun close to

500
00:21:53,980 --> 00:21:56,680
increase the amperage and heat for

501
00:21:56,680 --> 00:21:59,200
thinner gauge metals or fill in gaps the

502
00:21:59,200 --> 00:22:01,570
gun can be pulled away a little reducing

503
00:22:01,570 --> 00:22:03,940
the heat and limiting penetration you

504
00:22:03,940 --> 00:22:05,770
have to be careful not to pull the gun

505
00:22:05,770 --> 00:22:07,990
too far away or the world will get too

506
00:22:07,990 --> 00:22:10,840
cold it may not fuse you may even lose

507
00:22:10,840 --> 00:22:13,030
shielding gas coverage causing porosity

508
00:22:13,030 --> 00:22:15,640
in the weld be for most welding

509
00:22:15,640 --> 00:22:18,250
situations hold the gun close to start

510
00:22:18,250 --> 00:22:20,380
the weld then try to maintain a

511
00:22:20,380 --> 00:22:22,570
consistent quarter to three eighths of

512
00:22:22,570 --> 00:22:25,510
an inch wire stick out with ARC on our

513
00:22:25,510 --> 00:22:27,460
call characteristics of short-circuit

514
00:22:27,460 --> 00:22:30,130
transfer there is not a lot of arc force

515
00:22:30,130 --> 00:22:32,230
to help drive the filler metal into the

516
00:22:32,230 --> 00:22:35,680
weld for penetration and weld fusion you

517
00:22:35,680 --> 00:22:37,390
want to keep the wire and the arc

518
00:22:37,390 --> 00:22:39,100
directed at the leading edge of the

519
00:22:39,100 --> 00:22:42,220
molten puddle this is very subtle but

520
00:22:42,220 --> 00:22:43,840
where the wire hits the weld puddle

521
00:22:43,840 --> 00:22:46,450
makes a huge difference if the wire is

522
00:22:46,450 --> 00:22:48,430
directed at the back of the puddle with

523
00:22:48,430 --> 00:22:50,290
molten metal floating in front of the

524
00:22:50,290 --> 00:22:52,930
arc the weld bill up keeps taking the

525
00:22:52,930 --> 00:22:55,060
heat not allowing the base metal to get

526
00:22:55,060 --> 00:22:57,850
hot enough to melt the weld can actually

527
00:22:57,850 --> 00:23:00,220
float right on top without penetrating

528
00:23:00,220 --> 00:23:02,680
or fusing to the base metal this is a

529
00:23:02,680 --> 00:23:05,050
common problem a great-looking well that

530
00:23:05,050 --> 00:23:07,630
does not hold the model together for

531
00:23:07,630 --> 00:23:10,390
good weld fusion maintain the short wire
532
00:23:10,390 --> 00:23:12,340
stick out and stay ahead of the well

533
00:23:12,340 --> 00:23:14,710
keeping the wire on the leading edge of

534
00:23:14,710 --> 00:23:17,440
the puddle the wire feed gun can be held

535
00:23:17,440 --> 00:23:19,540
straight up and down and this will put

536
00:23:19,540 --> 00:23:21,490
all the heat of the arc right on the

537
00:23:21,490 --> 00:23:23,950
base metal fully automatic welding

538
00:23:23,950 --> 00:23:26,410
processes are often set up this way but

539
00:23:26,410 --> 00:23:28,930
in many fabrication situations the

540
00:23:28,930 --> 00:23:31,210
nozzle gets in the way making it

541
00:23:31,210 --> 00:23:33,430
difficult to see where you have to go

542
00:23:33,430 --> 00:23:35,710
or the well build up angle the gun

543
00:23:35,710 --> 00:23:38,110
slightly to provide better visibility of

544
00:23:38,110 --> 00:23:40,540
the molten puddle you do want to avoid

545
00:23:40,540 --> 00:23:43,510
angling the gun too much the increased

546
00:23:43,510 --> 00:23:45,910
wire stick out will reduce the amperage
547
00:23:45,910 --> 00:23:49,390
making the weld run colder welds can be

548
00:23:49,390 --> 00:23:51,400
made in either direction and this is

549
00:23:51,400 --> 00:23:53,200
another method the welder uses to

550
00:23:53,200 --> 00:23:55,480
control the penetration shape and

551
00:23:55,480 --> 00:23:58,900
quantity of well backhand or pulling the

552
00:23:58,900 --> 00:24:01,450
weld has a gun angle back towards the

553
00:24:01,450 --> 00:24:04,150
well the heat of the arc is directed

554
00:24:04,150 --> 00:24:06,400
onto the molten puddle keeping it more

555
00:24:06,400 --> 00:24:09,610
fluid generally this will build up more

556
00:24:09,610 --> 00:24:11,830
well be and you can watch the puddle

557
00:24:11,830 --> 00:24:14,920
with four hand or pushing the weld the

558
00:24:14,920 --> 00:24:16,930
gun is angle in the direction of travel

559
00:24:16,930 --> 00:24:19,330
the heat of the arc is directed away

560
00:24:19,330 --> 00:24:21,820
from the weld allowing the molten puddle

561
00:24:21,820 --> 00:24:25,000
to cool this tends to limit penetration

562
00:24:25,000 --> 00:24:27,610
produce a flatter well and you get to

563
00:24:27,610 --> 00:24:30,700
see where you're going with forehand you

564
00:24:30,700 --> 00:24:32,770
do need to be careful to keep the wire

565
00:24:32,770 --> 00:24:35,080
towards the leading edge and not float

566
00:24:35,080 --> 00:24:36,910
too much of the puddle in front of the

567
00:24:36,910 --> 00:24:39,640
arc for most wells you can just move the

568
00:24:39,640 --> 00:24:42,400
gun in a straight line a consistent wire

569
00:24:42,400 --> 00:24:44,380
stick out and travel speed will produce

570
00:24:44,380 --> 00:24:46,630
a nice-looking weld with uniform

571
00:24:46,630 --> 00:24:49,480
penetration and weld fusion you can also

572
00:24:49,480 --> 00:24:51,580
use a slight side-to-side motion

573
00:24:51,580 --> 00:24:54,070
watching the outside edges of the puddle

574
00:24:54,070 --> 00:24:55,540
to make sure the weld is staying

575
00:24:55,540 --> 00:24:58,270
straight for situations where a little

576
00:24:58,270 --> 00:25:01,150
more gun movement is required a you or

577
00:25:01,150 --> 00:25:04,090
an upside-down you will keep the arc at

578
00:25:04,090 --> 00:25:06,130
the front of the puddle there are

579
00:25:06,130 --> 00:25:08,410
exceptions but in water feet you want to

580
00:25:08,410 --> 00:25:10,810
avoid big wide gun movements it makes

581
00:25:10,810 --> 00:25:12,970
the puddle too difficult to control if

582
00:25:12,970 --> 00:25:15,490
you need more weld buildup you can

583
00:25:15,490 --> 00:25:17,770
increase the wire speed and voltage to

584
00:25:17,770 --> 00:25:20,410
squirt more wealth or switch to a bigger

585
00:25:20,410 --> 00:25:23,560
wire size for wide wells you can also

586
00:25:23,560 --> 00:25:26,080
stack overlapping load beads side by

587
00:25:26,080 --> 00:25:29,500
side the speed of travel how fast you

588
00:25:29,500 --> 00:25:32,080
move the gun depends on how much heat is

589
00:25:32,080 --> 00:25:34,780
at the weld you do need to move right

590
00:25:34,780 --> 00:25:37,090
along without hesitation to avoid
591
00:25:37,090 --> 00:25:39,370
excessive well build-up but you also

592
00:25:39,370 --> 00:25:41,740
have to give the arc enough time to melt

593
00:25:41,740 --> 00:25:44,050
the base metal allowing the filler metal

594
00:25:44,050 --> 00:25:46,970
to flow out and tie in on the sides

595
00:25:46,970 --> 00:25:49,340
to some extent you can see this by

596
00:25:49,340 --> 00:25:51,140
watching the edge of the molten puddle

597
00:25:51,140 --> 00:25:54,200
if the travel speed is too fast the

598
00:25:54,200 --> 00:25:56,809
metal doesn't have time to heat up the

599
00:25:56,809 --> 00:25:59,270
wall B will just stack up on top it may

600
00:25:59,270 --> 00:26:01,150
not even fuse to the base metal

601
00:26:01,150 --> 00:26:03,650
traveling too slow will generally put

602
00:26:03,650 --> 00:26:06,049
the wire and the arc on the weld build

603
00:26:06,049 --> 00:26:08,330
up causing excessive filler metal

604
00:26:08,330 --> 00:26:10,429
deposit and reducing the amount of heat

605
00:26:10,429 --> 00:26:13,190
to the base metal by speeding up or
606
00:26:13,190 --> 00:26:15,409
slowing down a little travel speed is

607
00:26:15,409 --> 00:26:18,200
the main option used during the weld to

608
00:26:18,200 --> 00:26:20,510
control the size of the weld and ensure

609
00:26:20,510 --> 00:26:23,360
good weld fusion make sure the puddle

610
00:26:23,360 --> 00:26:25,220
flows out and ties in on the sides

611
00:26:25,220 --> 00:26:27,650
watching the top of the puddle to avoid

612
00:26:27,650 --> 00:26:30,559
excessive weld build up one of the most

613
00:26:30,559 --> 00:26:32,870
important aspects for making successful

614
00:26:32,870 --> 00:26:34,880
welds is the voltage and wire speed

615
00:26:34,880 --> 00:26:37,970
settings basically the voltage controls

616
00:26:37,970 --> 00:26:39,500
of the potential amount of heat

617
00:26:39,500 --> 00:26:41,929
available to the weld and the wire speed

618
00:26:41,929 --> 00:26:44,150
determines the amount of weld build up

619
00:26:44,150 --> 00:26:46,820
there are two parts to making the final

620
00:26:46,820 --> 00:26:49,309
adjustment first the voltage and wire

621
00:26:49,309 --> 00:26:51,500
speed are adjusted to provide the amount

622
00:26:51,500 --> 00:26:54,080
of heat and weld deposit required for

623
00:26:54,080 --> 00:26:56,990
the specific lulling situation second

624
00:26:56,990 --> 00:26:59,480
and this is important the voltage and

625
00:26:59,480 --> 00:27:01,580
wire speed are always adjusted together

626
00:27:01,580 --> 00:27:04,159
to produce a stable transfer a filler

627
00:27:04,159 --> 00:27:06,080
metal from the welding wire into the

628
00:27:06,080 --> 00:27:09,169
molten puddle this means that any time

629
00:27:09,169 --> 00:27:11,419
you increase the wire speed for a bigger

630
00:27:11,419 --> 00:27:14,030
weld you also need to increase the

631
00:27:14,030 --> 00:27:16,669
voltage the same goes that if you want a

632
00:27:16,669 --> 00:27:18,710
little more heat for better penetration

633
00:27:18,710 --> 00:27:21,500
you can turn up the voltage but you also

634
00:27:21,500 --> 00:27:24,289
need to increase the wire speed tuning

635
00:27:24,289 --> 00:27:26,390
the two of them together for an optimum

636
00:27:26,390 --> 00:27:28,850
metal transfer in the welding industry

637
00:27:28,850 --> 00:27:31,370
wire speeds and voltage are set to

638
00:27:31,370 --> 00:27:33,289
produce the maximum amount of weld

639
00:27:33,289 --> 00:27:36,740
deposit and smaller shops this idea of

640
00:27:36,740 --> 00:27:38,900
maximum amount of weld is not always

641
00:27:38,900 --> 00:27:41,809
necessary or desirable especially while

642
00:27:41,809 --> 00:27:44,179
you're learning to weld a certain amount

643
00:27:44,179 --> 00:27:46,549
of heat is required though for good weld

644
00:27:46,549 --> 00:27:49,789
fusion welding charts located on the

645
00:27:49,789 --> 00:27:52,370
machine or in manuals generally reflect

646
00:27:52,370 --> 00:27:54,860
the minimum voltage and wire speeds for

647
00:27:54,860 --> 00:27:57,080
different metal thicknesses these charts

648
00:27:57,080 --> 00:27:58,970
do not always take into account the

649
00:27:58,970 --> 00:28:00,970
position of the weld or the amount of
650
00:28:00,970 --> 00:28:03,610
welder skill if you can handle the heat

651
00:28:03,610 --> 00:28:06,190
you can always increase the settings for

652
00:28:06,190 --> 00:28:07,570
higher deposit rates and better

653
00:28:07,570 --> 00:28:10,659
penetration the main purpose for the

654
00:28:10,659 --> 00:28:12,850
development of wire feed processes is

655
00:28:12,850 --> 00:28:16,360
speed for example if you're working with

656
00:28:16,360 --> 00:28:19,510
3/16 of an inch metal the wire speed is

657
00:28:19,510 --> 00:28:22,809
adjusted so that a 3/16 weld deposit can

658
00:28:22,809 --> 00:28:26,260
be comfortably made in one pass as well

659
00:28:26,260 --> 00:28:27,820
their skill and handling the wire feed

660
00:28:27,820 --> 00:28:30,370
gun increases higher wire speed settings

661
00:28:30,370 --> 00:28:32,860
can be used along the faster travel

662
00:28:32,860 --> 00:28:34,929
speeds to produce the same amount of

663
00:28:34,929 --> 00:28:38,350
weld in less time once the wire speed is

664
00:28:38,350 --> 00:28:40,630
set the voltage is adjusted to produce
665
00:28:40,630 --> 00:28:43,320
an optimum stable filler metal transfer

666
00:28:43,320 --> 00:28:46,000
the molten weld puddle should flow out

667
00:28:46,000 --> 00:28:48,010
to the sides and be very controllable

668
00:28:48,010 --> 00:28:50,110
with a finished weld be virtually

669
00:28:50,110 --> 00:28:53,320
spatter free if the voltage is set too

670
00:28:53,320 --> 00:28:55,690
high for the wire speed the length of

671
00:28:55,690 --> 00:28:57,880
the arc is increased putting more heat

672
00:28:57,880 --> 00:29:00,700
on the molten weld metal the puddle is

673
00:29:00,700 --> 00:29:02,890
more fluid and agitated making it

674
00:29:02,890 --> 00:29:05,020
difficult to control and causing

675
00:29:05,020 --> 00:29:07,870
excessive weld spatter if the voltage is

676
00:29:07,870 --> 00:29:10,450
set too low for the wire speed the arc

677
00:29:10,450 --> 00:29:12,580
length is shortened allowing the wire to

678
00:29:12,580 --> 00:29:15,190
run into the puddle the arc may be

679
00:29:15,190 --> 00:29:17,140
erratic and there's not enough heat to

680
00:29:17,140 --> 00:29:19,330
melt both the filler metal and the base

681
00:29:19,330 --> 00:29:21,549
metal so the puddle doesn't flow out on

682
00:29:21,549 --> 00:29:22,570
the side

683
00:29:22,570 --> 00:29:24,850
the finished weld bead will just stack

684
00:29:24,850 --> 00:29:27,730
up with short circuit transfer this

685
00:29:27,730 --> 00:29:29,950
optimum relationship between the wire

686
00:29:29,950 --> 00:29:31,960
speed and voltage can actually be

687
00:29:31,960 --> 00:29:33,870
adjusted by the sound of the arc

688
00:29:33,870 --> 00:29:36,400
starting with the voltage too high for

689
00:29:36,400 --> 00:29:38,830
the wire speed the arc sound is erratic

690
00:29:38,830 --> 00:29:41,950
as the voltages decrease our sound

691
00:29:41,950 --> 00:29:44,980
becomes more consistent with the voltage

692
00:29:44,980 --> 00:29:47,169
to roll for the wire speed the sound

693
00:29:47,169 --> 00:29:50,200
becomes erratic again the stable metal

694
00:29:50,200 --> 00:29:52,539
transfer is where the arc sound is most

695
00:29:52,539 --> 00:29:54,940
consistent you can do this while you're

696
00:29:54,940 --> 00:29:56,799
welding on some practice metal either

697
00:29:56,799 --> 00:29:59,080
adjusting the voltage or the wire speed

698
00:29:59,080 --> 00:30:01,120
if the dial on your machine is a

699
00:30:01,120 --> 00:30:03,909
rheostat and infinitely adjustable if

700
00:30:03,909 --> 00:30:06,820
the dial clicks in two ranges you cannot

701
00:30:06,820 --> 00:30:09,460
change this during the well regardless

702
00:30:09,460 --> 00:30:11,409
of where the wire speed and voltage are

703
00:30:11,409 --> 00:30:14,020
set you'll always want to tune the two

704
00:30:14,020 --> 00:30:14,950
of them together

705
00:30:14,950 --> 00:30:16,990
to provide the optimum nearly spatter

706
00:30:16,990 --> 00:30:20,139
free metal transfer now one of the

707
00:30:20,139 --> 00:30:22,149
biggest problems with gas metal arc

708
00:30:22,149 --> 00:30:25,120
welding is running to cold welding works
709
00:30:25,120 --> 00:30:27,549
best when the machine is set as hot as

710
00:30:27,549 --> 00:30:29,950
you can handle it more heat produces

711
00:30:29,950 --> 00:30:32,200
better weld fusion and smoother weld

712
00:30:32,200 --> 00:30:34,899
beads try setting up on different metal

713
00:30:34,899 --> 00:30:36,940
thicknesses tune the voltage and wire

714
00:30:36,940 --> 00:30:39,190
speeds together and make some practice

715
00:30:39,190 --> 00:30:41,409
weld if there's too much metal and you

716
00:30:41,409 --> 00:30:43,659
can't stay ahead of the puddle turn the

717
00:30:43,659 --> 00:30:45,850
settings down a little if you think you

718
00:30:45,850 --> 00:30:48,100
can handle a little more heat turn them

719
00:30:48,100 --> 00:30:51,010
up the final settings are determined by

720
00:30:51,010 --> 00:30:52,539
watching the molten puddle

721
00:30:52,539 --> 00:30:54,429
during the weld and examining the

722
00:30:54,429 --> 00:30:57,669
finished well be a smooth uniform bead

723
00:30:57,669 --> 00:31:00,279
will come with practice but the edges
724
00:31:00,279 --> 00:31:03,250
should be fused to the base metal if the

725
00:31:03,250 --> 00:31:05,350
edges are rolled over your travel speed

726
00:31:05,350 --> 00:31:07,899
may be too slow along with too low of a

727
00:31:07,899 --> 00:31:10,419
voltage and wire speed setting if the

728
00:31:10,419 --> 00:31:12,820
weld bead stacks up not flowing out on

729
00:31:12,820 --> 00:31:14,860
the sides you might be traveling too

730
00:31:14,860 --> 00:31:17,230
fast using too long of an electrode

731
00:31:17,230 --> 00:31:19,600
extension or the voltage and wire speed

732
00:31:19,600 --> 00:31:22,480
are set to low when there's excessive

733
00:31:22,480 --> 00:31:25,000
weld spatter the voltage is probably too

734
00:31:25,000 --> 00:31:27,490
high for the wire speed if the world is

735
00:31:27,490 --> 00:31:29,350
kind of flattened out and all over the

736
00:31:29,350 --> 00:31:31,360
place you might be running hotter than

737
00:31:31,360 --> 00:31:32,110
you can handle

738
00:31:32,110 --> 00:31:34,330
with a wire directed at the back of the

739
00:31:34,330 --> 00:31:36,760
puddle when the finished weld beam has

740
00:31:36,760 --> 00:31:39,519
the correct size shape and it's fused to

741
00:31:39,519 --> 00:31:41,889
the base metal that's as good as it gets

742
00:31:41,889 --> 00:31:44,139
well that's about all there is to the

743
00:31:44,139 --> 00:31:45,880
fundamentals of gas metal arc welding

744
00:31:45,880 --> 00:31:49,539
have a good clean ground use a short

745
00:31:49,539 --> 00:31:51,809
electrode stick out for a hot start

746
00:31:51,809 --> 00:31:55,450
maintain 1/4 to 3/8 wire extension for

747
00:31:55,450 --> 00:31:58,240
consistent penetration back the gun away

748
00:31:58,240 --> 00:32:00,669
a little to cool the puddle for filling

749
00:32:00,669 --> 00:32:04,029
gaps push the well to limit penetration

750
00:32:04,029 --> 00:32:05,760
and to see where you're going

751
00:32:05,760 --> 00:32:09,519
pull the weld form or well build up set

752
00:32:09,519 --> 00:32:11,409
the voltage and wire speed high enough

753
00:32:11,409 --> 00:32:14,260
for good filler metal fusion and to the

754
00:32:14,260 --> 00:32:16,710
settings for a stable metal transfer

755
00:32:16,710 --> 00:32:19,480
move slow enough to allow the puddle to

756
00:32:19,480 --> 00:32:22,210
flow out and tie in on the sides but

757
00:32:22,210 --> 00:32:23,980
fast enough to keep the wire on the

758
00:32:23,980 --> 00:32:25,870
leading edge of the puddle and avoid

759
00:32:25,870 --> 00:32:27,309
excessive weld bill

760
00:32:27,309 --> 00:32:30,519
love so far all the demonstrations have

761
00:32:30,519 --> 00:32:33,220
been in the flat position for horizontal

762
00:32:33,220 --> 00:32:36,070
we'll be welding across because the weld

763
00:32:36,070 --> 00:32:38,440
bill up needs to solidify quicker so

764
00:32:38,440 --> 00:32:40,749
that it doesn't sag or drip slightly

765
00:32:40,749 --> 00:32:43,029
angle the gun up and in the direction of

766
00:32:43,029 --> 00:32:45,429
travel keeping the heat of the arc away

767
00:32:45,429 --> 00:32:48,070
from the molten weld buildup move right
768
00:32:48,070 --> 00:32:50,200
along with the wire at the front of the

769
00:32:50,200 --> 00:32:52,720
puddle and maintain a uniform travel

770
00:32:52,720 --> 00:32:55,269
speed and electrode stick out if the

771
00:32:55,269 --> 00:32:57,249
weld bead sags make sure you're not

772
00:32:57,249 --> 00:32:59,289
directing the arc back onto the puddle

773
00:32:59,289 --> 00:33:02,080
then try increasing the speed of travel

774
00:33:02,080 --> 00:33:05,169
to keep the base metal cooler vertical

775
00:33:05,169 --> 00:33:07,059
wells with short-circuit gas metal arc

776
00:33:07,059 --> 00:33:09,720
welding are made downhill or down Han

777
00:33:09,720 --> 00:33:12,850
heat rises so you'll be welding away

778
00:33:12,850 --> 00:33:14,980
from the heat which keeps the base metal

779
00:33:14,980 --> 00:33:17,619
cooler angle the gun up a little using

780
00:33:17,619 --> 00:33:19,389
the heat of the arc to help hold the

781
00:33:19,389 --> 00:33:21,820
puddle up you can either run straight

782
00:33:21,820 --> 00:33:23,889
down or use a slight side-to-side
783
00:33:23,889 --> 00:33:26,799
movement move fast enough to stay ahead

784
00:33:26,799 --> 00:33:29,080
of the molten metal keeping the wire on

785
00:33:29,080 --> 00:33:30,850
the leading edge for penetration and

786
00:33:30,850 --> 00:33:32,950
watching the sides to keep the weld

787
00:33:32,950 --> 00:33:36,039
straight if you can't travel fast enough

788
00:33:36,039 --> 00:33:38,499
and stay in control you may need to turn

789
00:33:38,499 --> 00:33:40,659
down the wire speed and voltage so the

790
00:33:40,659 --> 00:33:42,899
filler metal isn't quite so fluid

791
00:33:42,899 --> 00:33:45,999
overhead welds with wire feed like every

792
00:33:45,999 --> 00:33:48,129
other welding process are not difficult

793
00:33:48,129 --> 00:33:50,919
they're just awkward the real key to

794
00:33:50,919 --> 00:33:52,450
welding overhead is finding a

795
00:33:52,450 --> 00:33:54,490
comfortable position so that you have

796
00:33:54,490 --> 00:33:56,850
complete control of the wire feed gun

797
00:33:56,850 --> 00:33:59,259
angle the gun in the direction of travel

798
00:33:59,259 --> 00:34:01,629
to keep the heat of the arc off the weld

799
00:34:01,629 --> 00:34:03,820
build up while you're learning dwell

800
00:34:03,820 --> 00:34:06,340
overhead keep moving don't try to build

801
00:34:06,340 --> 00:34:08,649
up too much weld as you gain experience

802
00:34:08,649 --> 00:34:11,260
you can carry more metal by holding the

803
00:34:11,260 --> 00:34:13,060
gun straighter up and down with a little

804
00:34:13,060 --> 00:34:15,460
side-to-side movement if you have

805
00:34:15,460 --> 00:34:17,440
trouble welding overhead make sure

806
00:34:17,440 --> 00:34:19,119
you're maintaining the correct wire

807
00:34:19,119 --> 00:34:21,250
extension and try different travel

808
00:34:21,250 --> 00:34:23,589
speeds you want to go slow enough to let

809
00:34:23,589 --> 00:34:25,690
the puddle spread out and tie in but

810
00:34:25,690 --> 00:34:27,969
fast enough to avoid overheating and

811
00:34:27,969 --> 00:34:30,550
excessive well build up one of the

812
00:34:30,550 --> 00:34:32,859
advantages the wire feed is ease of

813
00:34:32,859 --> 00:34:35,109
operation it won't take long for you to

814
00:34:35,109 --> 00:34:37,629
become comfortable running weld beads so

815
00:34:37,629 --> 00:34:40,630
try practicing weld joints to the

816
00:34:40,630 --> 00:34:43,239
first step is metal preparation you

817
00:34:43,239 --> 00:34:46,300
absolutely have to clean any paint rust

818
00:34:46,300 --> 00:34:48,610
or grease from the metal even the mill

819
00:34:48,610 --> 00:34:50,800
scale which is the dark layer on the

820
00:34:50,800 --> 00:34:53,710
surface a new metal surface impurities

821
00:34:53,710 --> 00:34:55,690
will often cause little gas pockets

822
00:34:55,690 --> 00:34:58,030
which is porosity in the finished weld

823
00:34:58,030 --> 00:35:01,060
bead impurities also take the heat that

824
00:35:01,060 --> 00:35:02,530
should be going to the base metal

825
00:35:02,530 --> 00:35:05,050
limiting weld fusion especially at the

826
00:35:05,050 --> 00:35:07,270
edges because the metal doesn't get hot
827
00:35:07,270 --> 00:35:09,970
enough to melt in many situations you'll

828
00:35:09,970 --> 00:35:11,530
find that it takes longer to get the

829
00:35:11,530 --> 00:35:13,600
metal ready to weld than it does to

830
00:35:13,600 --> 00:35:16,330
actually weld it there are four kinds of

831
00:35:16,330 --> 00:35:19,810
weld joints but joints lap joints tea

832
00:35:19,810 --> 00:35:22,480
joints and corner joints let's start

833
00:35:22,480 --> 00:35:24,820
with the butt joints extremely thin

834
00:35:24,820 --> 00:35:26,770
gauge metal like auto body metal is

835
00:35:26,770 --> 00:35:29,230
generally lap welded but if your project

836
00:35:29,230 --> 00:35:31,930
requires a butt weld take the time to

837
00:35:31,930 --> 00:35:34,750
get a perfect fit any gaps will cause

838
00:35:34,750 --> 00:35:37,210
the edges to melt away ripping open a

839
00:35:37,210 --> 00:35:40,330
hole in the flat position push the well

840
00:35:40,330 --> 00:35:42,880
to help control penetration but if at

841
00:35:42,880 --> 00:35:45,580
all possible vertical down works best on
842
00:35:45,580 --> 00:35:47,620
thin gauge metals because the metal

843
00:35:47,620 --> 00:35:50,140
stays cooler as the metal gets thicker

844
00:35:50,140 --> 00:35:52,630
start leaving a little gap to allow for

845
00:35:52,630 --> 00:35:55,510
deeper welds keep it uniform though so

846
00:35:55,510 --> 00:35:58,000
you can maintain a constant travel speed

847
00:35:58,000 --> 00:36:00,970
a good fit up makes it easier to produce

848
00:36:00,970 --> 00:36:03,100
both of good-looking and strong well

849
00:36:03,100 --> 00:36:06,520
join ideally on butt welds you want a

850
00:36:06,520 --> 00:36:09,070
hundred percent penetration this won't

851
00:36:09,070 --> 00:36:11,440
always happen but you do want the weld

852
00:36:11,440 --> 00:36:14,230
deep in the joint for maximum strength

853
00:36:14,230 --> 00:36:16,570
you can always grind out the opposite

854
00:36:16,570 --> 00:36:18,580
side and run a weld beat for complete

855
00:36:18,580 --> 00:36:20,800
penetration when the metal gets up

856
00:36:20,800 --> 00:36:22,840
around an eighth of an inch thick you

857
00:36:22,840 --> 00:36:24,910
can leave a little wider gap or even

858
00:36:24,910 --> 00:36:27,040
bevel the edges a little besides

859
00:36:27,040 --> 00:36:29,440
providing for a deeper weld the corners

860
00:36:29,440 --> 00:36:30,970
of the metal heat up quickly

861
00:36:30,970 --> 00:36:33,040
helping the filler metal fuse at the

862
00:36:33,040 --> 00:36:35,650
outside edges if the pieces are jammed

863
00:36:35,650 --> 00:36:37,810
together on fit up you can take a

864
00:36:37,810 --> 00:36:40,270
grinder on edge and groove the joint on

865
00:36:40,270 --> 00:36:43,360
thicker metal bevel the edges and tack

866
00:36:43,360 --> 00:36:45,040
the pieces together with around the

867
00:36:45,040 --> 00:36:47,460
sixteenth to an eighth of an inch gap

868
00:36:47,460 --> 00:36:50,740
using a new motion make sure the arc is

869
00:36:50,740 --> 00:36:52,540
directed towards the front of the puddle

870
00:36:52,540 --> 00:36:54,730
at the edge of the metal

871
00:36:54,730 --> 00:36:57,220
bring the wire across the gap slightly

872
00:36:57,220 --> 00:36:59,260
back on the molten puddle to the front

873
00:36:59,260 --> 00:37:01,990
edge on the other side then just back

874
00:37:01,990 --> 00:37:03,940
and forth keeping the arc deep in the

875
00:37:03,940 --> 00:37:04,510
joint

876
00:37:04,510 --> 00:37:07,270
if you squirt the wire into the open gap

877
00:37:07,270 --> 00:37:10,210
it will burn off leaving cold wire in

878
00:37:10,210 --> 00:37:12,700
the joint depending on the thickness of

879
00:37:12,700 --> 00:37:14,710
the metal you may not be able to fill

880
00:37:14,710 --> 00:37:17,560
the joint in one pass to finish the well

881
00:37:17,560 --> 00:37:19,960
you can carry a little more metal by

882
00:37:19,960 --> 00:37:22,990
using a slight side-to-side motion keep

883
00:37:22,990 --> 00:37:24,700
the arc on the front edge of the weld

884
00:37:24,700 --> 00:37:26,859
puddle going wide enough to cover the

885
00:37:26,859 --> 00:37:29,619
edges of the bevel the idea is not to
886
00:37:29,619 --> 00:37:31,930
put down a whole lot more well than you

887
00:37:31,930 --> 00:37:34,570
need the amount of well build up should

888
00:37:34,570 --> 00:37:36,400
equal the thickness of the metal but

889
00:37:36,400 --> 00:37:38,650
stacking filler metal on top will not do

890
00:37:38,650 --> 00:37:40,720
any good if the weld isn't deep in the

891
00:37:40,720 --> 00:37:43,780
joint lap joints are very simple to well

892
00:37:43,780 --> 00:37:45,910
and this is called a fill it well on

893
00:37:45,910 --> 00:37:48,609
thinner gauge metals use a lot of tacks

894
00:37:48,609 --> 00:37:51,190
to keep the metal from separating if the

895
00:37:51,190 --> 00:37:53,589
weld bead will be cosmetic you can grind

896
00:37:53,589 --> 00:37:55,720
these tacks flush to avoid hops in the

897
00:37:55,720 --> 00:37:58,270
finished weld bead push the weld in the

898
00:37:58,270 --> 00:38:00,849
flat position to control penetration or

899
00:38:00,849 --> 00:38:03,310
better yet position the joint for a

900
00:38:03,310 --> 00:38:06,550
vertical down on heavier metals the weld
901
00:38:06,550 --> 00:38:09,190
should come up and out a distance equal

902
00:38:09,190 --> 00:38:11,319
to the thickness of the metal try

903
00:38:11,319 --> 00:38:13,540
holding the gun nearly perpendicular to

904
00:38:13,540 --> 00:38:15,790
the joint for a crown weld bead or

905
00:38:15,790 --> 00:38:18,280
slightly angle the gun to push the well

906
00:38:18,280 --> 00:38:21,220
for a flatter bead pulling the weld may

907
00:38:21,220 --> 00:38:23,530
cause the finish weld bead to hop up in

908
00:38:23,530 --> 00:38:24,099
the middle

909
00:38:24,099 --> 00:38:26,890
aim the wire into the joint the edge of

910
00:38:26,890 --> 00:38:28,810
the top piece will heat up and fuse

911
00:38:28,810 --> 00:38:31,060
easier than the bottom so make sure at

912
00:38:31,060 --> 00:38:32,650
least some of the heat of the arc is

913
00:38:32,650 --> 00:38:35,200
directed at the bottom piece if the weld

914
00:38:35,200 --> 00:38:37,450
bead is not uniform you may need to

915
00:38:37,450 --> 00:38:39,339
adjust the angle of the gun for the

916
00:38:39,339 --> 00:38:41,710
correct shape the amount of weld deposit

917
00:38:41,710 --> 00:38:44,020
depends both on your travel speed and

918
00:38:44,020 --> 00:38:46,390
the wire speed setting you can use a

919
00:38:46,390 --> 00:38:48,579
slight gun movement to carry more metal

920
00:38:48,579 --> 00:38:51,040
but if you can handle the heat increase

921
00:38:51,040 --> 00:38:53,020
the voltage and wire speed to deposit

922
00:38:53,020 --> 00:38:56,170
more filler metal a Philip well is also

923
00:38:56,170 --> 00:38:58,690
used for tea joints and this is very

924
00:38:58,690 --> 00:39:01,750
similar to a lap weld vertical down fill

925
00:39:01,750 --> 00:39:03,490
it's on thinner metal seems to produce

926
00:39:03,490 --> 00:39:05,980
the nicest looking weld but if there is

927
00:39:05,980 --> 00:39:07,720
a drawback to the gas metal arc welding

928
00:39:07,720 --> 00:39:08,400
process

929
00:39:08,400 --> 00:39:10,620
this it is vertical down wells on

930
00:39:10,620 --> 00:39:13,080
thicker metal a higher voltage is

931
00:39:13,080 --> 00:39:16,290
necessary to ensure good weld fusion to

932
00:39:16,290 --> 00:39:18,720
keep a stable metal transfer it also

933
00:39:18,720 --> 00:39:21,390
means a faster wire speed to the point

934
00:39:21,390 --> 00:39:23,250
where you may not be able to handle the

935
00:39:23,250 --> 00:39:26,340
quantity of molten well coming down you

936
00:39:26,340 --> 00:39:28,980
can make these wells by running hot with

937
00:39:28,980 --> 00:39:30,870
the faster travel speed to prevent

938
00:39:30,870 --> 00:39:32,340
excessive well buildup

939
00:39:32,340 --> 00:39:34,890
then multi passing to increase the size

940
00:39:34,890 --> 00:39:37,560
of the weld corner joints ARF it up

941
00:39:37,560 --> 00:39:39,870
several ways the edges can be lapped

942
00:39:39,870 --> 00:39:41,940
with the weld bead on the outside edge

943
00:39:41,940 --> 00:39:44,820
for thin gauge metal try to position the

944
00:39:44,820 --> 00:39:47,700
joint for a vertical down on thicker
945
00:39:47,700 --> 00:39:50,250
metals bevel or grind a groove on one

946
00:39:50,250 --> 00:39:52,380
edge if you're concerned at all about

947
00:39:52,380 --> 00:39:54,690
the strength of the joint a filler well

948
00:39:54,690 --> 00:39:57,300
can also be added to the inside but this

949
00:39:57,300 --> 00:39:59,400
will tend to draw the pieces in the

950
00:39:59,400 --> 00:40:01,860
direction of the fill it corners can

951
00:40:01,860 --> 00:40:03,930
also be fit up by lining up the inside

952
00:40:03,930 --> 00:40:06,900
edges more or less forming a bevel try

953
00:40:06,900 --> 00:40:08,640
leaving a little gap for complete

954
00:40:08,640 --> 00:40:11,130
penetration this type of corner provides

955
00:40:11,130 --> 00:40:13,530
a good-looking strong weld joint that's

956
00:40:13,530 --> 00:40:16,020
easy to well practice these different

957
00:40:16,020 --> 00:40:18,090
weld joints watch the molten puddle

958
00:40:18,090 --> 00:40:20,700
examine the finished weld beat and even

959
00:40:20,700 --> 00:40:22,500
try breaking the wells to see if the
960
00:40:22,500 --> 00:40:24,570
filler metal is fusing to the base metal

961
00:40:24,570 --> 00:40:26,940
a big part of learning to weld is

962
00:40:26,940 --> 00:40:30,620
figuring out what works for you

963
00:40:30,930 --> 00:40:36,540
[Music]

964
00:40:38,140 --> 00:40:40,610
we've been demonstrating all position

965
00:40:40,610 --> 00:40:42,290
welding and weld joints with a

966
00:40:42,290 --> 00:40:44,420
low-voltage range short-circuit metal

967
00:40:44,420 --> 00:40:47,390
transfer for faster deposit rates or

968
00:40:47,390 --> 00:40:49,910
better penetration using the same filler

969
00:40:49,910 --> 00:40:52,190
wire you can turn up the voltage and

970
00:40:52,190 --> 00:40:55,550
wire speed over 22 volts you'll have an

971
00:40:55,550 --> 00:40:57,980
open arc and globular transfer with

972
00:40:57,980 --> 00:41:02,120
carbon dioxide or 7525 or spray transfer

973
00:41:02,120 --> 00:41:05,300
with an argon rich gas from the welders

974
00:41:05,300 --> 00:41:07,820
point of view these are similar while it

975
00:41:07,820 --> 00:41:10,130
is high speed welding it's also very

976
00:41:10,130 --> 00:41:12,590
simple because of the amount of heat and

977
00:41:12,590 --> 00:41:14,660
filler metal these are generally used

978
00:41:14,660 --> 00:41:16,550
only in the flat position or for

979
00:41:16,550 --> 00:41:19,130
horizontal Filat which is basically flat

980
00:41:19,130 --> 00:41:21,860
the contact tip should be slightly

981
00:41:21,860 --> 00:41:24,260
recessed and use a longer electrode

982
00:41:24,260 --> 00:41:26,720
extension around a half an inch angle

983
00:41:26,720 --> 00:41:28,670
the gun slightly to push the weld

984
00:41:28,670 --> 00:41:30,830
directing some of the heat away from the

985
00:41:30,830 --> 00:41:33,650
molten metal aim the wire into the joint

986
00:41:33,650 --> 00:41:36,050
pull the trigger and try to stay ahead

987
00:41:36,050 --> 00:41:38,480
of the weld build up when you stop

988
00:41:38,480 --> 00:41:41,120
examine the finished well you may need

989
00:41:41,120 --> 00:41:42,950
to adjust the travel speed and the gun

990
00:41:42,950 --> 00:41:45,440
angle for proper weld deposit with the

991
00:41:45,440 --> 00:41:47,690
higher voltage open art you can no

992
00:41:47,690 --> 00:41:49,640
longer use the sound to adjust the

993
00:41:49,640 --> 00:41:51,800
voltage and wire speed settings but they

994
00:41:51,800 --> 00:41:54,440
still need to be tuned together the wire

995
00:41:54,440 --> 00:41:56,630
speed is set to provide the required

996
00:41:56,630 --> 00:41:59,180
amount of weld all machines like this

997
00:41:59,180 --> 00:42:01,670
the dial indicates a percentage of the

998
00:42:01,670 --> 00:42:04,280
maximum wire speed which is generally

999
00:42:04,280 --> 00:42:06,890
around 700 inches per minute each

1000
00:42:06,890 --> 00:42:09,860
increment represents 70 inches per

1001
00:42:09,860 --> 00:42:13,550
minute of wire 403 v wire start with a

1002
00:42:13,550 --> 00:42:15,530
minimum of four hundred and twenty

1003
00:42:15,530 --> 00:42:18,170
inches per minute the voltage setting
1004
00:42:18,170 --> 00:42:20,540
starting around twenty five volts will

1005
00:42:20,540 --> 00:42:22,250
vary depending on the shielding gas

1006
00:42:22,250 --> 00:42:25,310
blend the voltage regulates the actual

1007
00:42:25,310 --> 00:42:27,860
arc length so if the bolts are set too

1008
00:42:27,860 --> 00:42:30,200
high the arc gap will be long

1009
00:42:30,200 --> 00:42:32,030
throwing heat on the molten puddle and

1010
00:42:32,030 --> 00:42:34,790
making it difficult to control if the

1011
00:42:34,790 --> 00:42:37,130
voltage is set too low the wire runs

1012
00:42:37,130 --> 00:42:39,320
into the puddle kind of exploding and

1013
00:42:39,320 --> 00:42:42,320
causing excessive weld spatter adjust

1014
00:42:42,320 --> 00:42:44,990
the voltage to obtain a short arc length

1015
00:42:44,990 --> 00:42:48,040
globular transfer with carbon dioxide or

1016
00:42:48,040 --> 00:42:51,380
7525 will produce weld spatter you

1017
00:42:51,380 --> 00:42:54,020
really can't get away from it spray

1018
00:42:54,020 --> 00:42:56,630
transfer with an argon rich gas and the
1019
00:42:56,630 --> 00:42:58,460
wire speed and voltage tuned for a short

1020
00:42:58,460 --> 00:43:00,980
arc length will produce a nearly spatter

1021
00:43:00,980 --> 00:43:04,580
free weld either globular or spray can

1022
00:43:04,580 --> 00:43:07,070
be used on any metal thickness that can

1023
00:43:07,070 --> 00:43:09,650
handle that amount of heat an industry

1024
00:43:09,650 --> 00:43:12,440
though spray transfer is considered most

1025
00:43:12,440 --> 00:43:14,570
efficient for metals up to 3/8 of an

1026
00:43:14,570 --> 00:43:17,180
inch thick other welding processes are

1027
00:43:17,180 --> 00:43:19,310
used for thicker metal to provide even

1028
00:43:19,310 --> 00:43:21,650
more well deposit and faster welding

1029
00:43:21,650 --> 00:43:27,050
speeds well that's about it I hope I've

1030
00:43:27,050 --> 00:43:29,180
given you an idea of what to do and what

1031
00:43:29,180 --> 00:43:31,910
to look for wire feed welding is all

1032
00:43:31,910 --> 00:43:33,650
about putting down the required amount

1033
00:43:33,650 --> 00:43:36,070
of well with good filler metal fusion

1034
00:43:36,070 --> 00:43:38,780
the size of the weld is controlled by

1035
00:43:38,780 --> 00:43:41,150
the wire speed setting and travel speed

1036
00:43:41,150 --> 00:43:43,490
the heat at the weld is determined by

1037
00:43:43,490 --> 00:43:46,430
the voltage travel speed and electrode

1038
00:43:46,430 --> 00:43:49,010
extension become familiar with your

1039
00:43:49,010 --> 00:43:50,990
equipment and maintain it to keep the

1040
00:43:50,990 --> 00:43:53,660
wire feeding smoothly clean the metal

1041
00:43:53,660 --> 00:43:56,150
and take the time for a good joint fit

1042
00:43:56,150 --> 00:43:59,119
up practice the welds and weld joints in

1043
00:43:59,119 --> 00:44:02,000
different positions always tune the

1044
00:44:02,000 --> 00:44:03,830
voltage and wire speed for a stable

1045
00:44:03,830 --> 00:44:06,890
metal transfer keep the wire on the

1046
00:44:06,890 --> 00:44:08,150
leading edge of the puddle for

1047
00:44:08,150 --> 00:44:10,700
penetration watching the sides and the

1048
00:44:10,700 --> 00:44:14,000
weld build up above all else have fun

1049
00:44:14,000 --> 00:44:15,750
with this and work safely

1050
00:44:15,750 --> 00:44:24,660
[Music]

1051
00:44:35,640 --> 00:00:00,000
me