Assessments - 4, GPA: 3.8
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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 ! WARNING 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. Base Metal Normal Heat, Wire Speed, Travel Speed Heat Too Low Heat Too High Wire Speed Too Fast Travel Speed Too Fast Travel Speed Too Slow Wire Speed Too Slow Figure 10 - Weld Appearance 8 WG3020 Welding Guidelines (Continued) WELDING POSITIONS Four basic welding positions can be used; flat, horizontal, vertical, and 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 45. travel angle and 45. 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 60. angle. NOTE: Remember to remove the slag before each pass for gasless process. Figure 11 - Weld Passes Cover Filler Root Figure 12 - Multiple Weld Passes PUSH VS PULL TECHNIQUE The type and thickness of the work piece dictates which way to point the gun nozzle. For thin materials (18 gauge and up) and all aluminum, the nozzle should point out in front of the weld puddle and push the puddle across the workpiece. For thicker steel, the nozzle should point into the puddle to increase weld penetration. This is called backhand or pull technique (See Figure 13). ALUMINUM WELDING Any aluminum surface to be welded, must be cleaned thoroughly with a stainless steel brush to eliminate any oxides on the weld and grounding surface. 100% Argon must be used when welding aluminum. If Argon is not used, metal penetration is unlikely. PULL Figure 13 PUSH Supply Cable Replacement 1. Verify that welder is OFF and power cord disconnected. 2. Remove welder cover to expose the ON/OFF switch. 3. Disconnect the black and white power cord wires connected to the ON/OFF switch. 4. Disconnect the green power cord wire connected to welder frame. 5. Loosen the cord strain screw(s) and pull cord out of strain relief. 6. Install new cord in reverse order. 9 For Information About This Product, Call 1-800-746-5641 Troubleshooting Chart - Welder Symptom Possible Cause(s) Corrective Action No output 1. Duty cycle exceeded 2. Poor work clamp connection 3. Defective power switch 4. Blown breaker or fuse 1. Allow welder to cool until ON/OFF Switch lamp goes out 2. Be sure all connections are secure, and attaching surface is clean 3. Replace switch 4. Reduce circuit load, reset breaker or replace fuse Wire tangles at drive roller 1. Wrong size gun tip 2. Gun liner clogged or damaged 3. Gun tip clogged or damaged 4. Feed roller worn 5. Not enough tension 1. Use proper size gun tip 2. Clean or replace gun liner 3. Clean or replace gun tip 4. Replace 5. Tighten tensioning screw Gun nozzle arcs to work surface Slag inside gun nozzle Clean slag from gun nozzle Work clamp and/or cable gets hot 1. Poor contact 2. Using an extension cord with excessive length 1. Be sure all connections are secure, and attaching surface is clean 2. Never use an extension cord longer than 20 ft Wire does not feed 1. Wire jammed 2. Out of wire 3. Not enough tension 4. Wire liner worn 5. Fuse blown 6. Wire disconnected internally 7. Contact tip clogged 1. Re...