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work piece material thickness all affect
the speed of travel necessary for
completing a good weld (See Fig. 11).
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
clean-up is done with a wire brush.
NOTE: When making multiple weld
passes, remove the slag before each
pass.
WELDING POSITIONS
Four basic welding positions can be
used; flat, horizontal, vertical, and
!
WARNING
8
Wire Feed Arc Welder
Welding Guidelines (Continued)
overhead. Welding in the flat position
is easier than any of the others because
welding speed can be increased, the
molten metal has less tendency to run,
better penetration can be achieved,
and the work is less fatiguing. Welding
is performed with the wire at a 45º
travel angle and 45º work angle.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these
welds.
Overhead welding is the least desirable
position as it is the most difficult and
dangerous. Heat setting and wire
selection will vary depending upon the
position.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
technical manual.
WELD PASSES
Sometimes more then one pass is
necessary to fill the joint. The root pass
is first, followed by filler passes and the
cover pass. If the pieces are thick, it may
be necessary to bevel the edges that
are joined at a 60º angle.
NOTE: Remember to remove the slag
before each pass for gasless process.
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Normal Heat, Wire Speed, Travel
Speed
Heat Too Low
Heat Too High
Wire Speed Too Fast
Wire Speed Too Slow
Travel Speed Too Slow
Travel Speed Too Fast
Base Metal
Figure 11 - Weld Appearance
Figure 12 - Weld Passes
Cover
Filler
Root
Figure 13 - Multiple Weld Passes