9
Model WG2040, WG2044, WG2045, WG3000
Factors such as diameter and type of
weld wire, amperage, position, and work
piece material thickness all effect the
speed of travel necessary for completing
a good weld (See Fig. 15). 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-CORED 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.
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 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
!
WARNING
Welding Guidelines
(Continued)
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 WT2530. Call 800-746-
5641 to order.
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 18).
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. Remember to
remove the slag before each pass for
gasless process.
ALUMINUM WELDING
Any aluminum surface to be welded,
must be cleaned thoroughly with a
www.chpower.com
Figure 16 - Weld Passes
Cover
Filler
Root
Figure 17 - Multiple Weld Passes
PUSH
PULL
Figure 18
