Assessments - 3, GPA: 4
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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. When making multiple weld passes, remove the slag before each pass. 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 than 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. Remember to remove the slag before each pass for the FCAW process. Figure 10 - Weld Passes Cover Filler Root Figure 11 - Multiple Weld Passes 9 Wire Feed Arc Welder Welding Guidelines (Continued) ALUMINUM WELDING Any aluminum surface to be welded, must be cleaned thoroughly with a stainless steel brush to eliminate any oxidation on the weld and grounding surface. 100% Argon shielding gas must be used when welding aluminum. If 100% Argon is not used, metal penetration is unlikely. A Teflon® wire liner, smooth-groove drive roller and aluminum contact tips are recommended when welding aluminum. Campbell Hausfeld offers these parts in Kit WT2532. Call 1-800746- 5641 to order. PUSH VS PULL TECHNIQUE The type and thickness of the work piece dictates which way to point the torch nozzle. For thin materials (18 gauge and smaller) 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 12). PULL PUSH Figure 12 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. Tripped circuit breaker 4. Blown breaker or fuse 1. Allow welder to cool until lamp goes out 2. Be sure all connections are secure, and attaching surface is clean 3. Reset by pushing button on back of unit 4. Reduce circuit load, reset breaker or replace fuse Wire tangles at drive roller 1. Wrong size contact tip 2. Torch liner clogged or damaged 3. Contact tip clogged or damaged 4. Drive roller worn 5. Not enough tension 1. Use proper size contact tip 2. Clean or replace wire liner 3. Clean or replace contact tip 4. Replace 5. Tighten tension knob Gun nozzle arcs to work surface 1. Slag inside gun nozzle 2. Insulation ring melted/expired 1. Clean slag from gun nozzle 2. Replace 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. Wire disconnected internally 6. Contact tip clogged 1. Reload wire 2. Replace wire spool 3. Tighten tension knob if wire is slipping 4. Replace liner 5. Call 1-800-746-5641 for assistance 6. Replace contact tip (Aluminum) Wire burns back into tip or (Aluminum) Metal bubbles or burns through 1. Wire speed too slow 2. Travel speed too slow or heat is too high 1. Run speed in 7 - 10 range 2. Increase the travel speed or reduce heat settings Weld pops and sputters 1. Wire speed setting 2. Contact tip size too large 3. Polarity set incorrectly 4. Drive roller slipping 5. Gas bottle empty 1. Tune in correct setting (1-5 mild steel; 5-10 aluminum) 2. Replace contact tip 3. Reverse polarity 4. Increase tension 5. Replace gas bottle 10 Models WG3080, WG3090 and WG4130 For Information About This Product Call 1-800-746-5641 Troubleshooting Chart - Welds Symptom Possible Cause(s) Corrective Action Bead is intermittently too thin 1. Inconsistent travel speed 2. Output heat setting too low 1. Decrease and maintain constant travel speed 2. Increase output heat setting Bead is intermittently too thick 1. Slow and...
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