corners, short runs and small radii. It also provides the begin-
ner with a chance to determine the correct balance of heat
and pressure required to produce a good weld.
1. Install the round tip and allow for warm-up time. Hold the
welder in one hand and weld rod in the other hand.
2. Preheat the base material at the start of the weld by fan-
ning the heat about ½” from the material’s surface.
3. Hold the rod, which has been precut at a 60º angle, per-
pendicular to the joint of the material, and slightly above
the preheated point, with the face of the 60º cut toward
the direction of the weld.
4. Direct the heat to the beveled surface of the material and
the bottom and front surfaces of the rod. Continue the
fanning motion of the tip. Make sure that the air stream is
directed straight to the joint of the rod and beveled area.
When the rod and the base material become shiny and
“tacky”, touch the rod material. They will stick together.
5. Now lean the rod forward in the direction of the weld.
Push the rod down so that the first part will adhere and not
“skid”. Maintain enough pressure on the rod so that the
softened end of the rod presses into the softened surface
of the material.
Flow lines (see Figure 3a) will appear on sides of the rod.
A small wave of softened material, consisting of fused rod
and base material, will flow in the bevel in front of the rod,
if the pressure is being evenly and constantly applied.
6. Now lean the rod back at a slight angle, away from the
direction of the weld, causing the rod to bend just above
the point where it is flowing into the bevel. Maintain the
fanning motion with the welder tip and enough pressure
on the rod while proceeding with the weld.
Generally speaking, the base material will take more
heat than the rod, although the distribution of the heat
necessary can be determined by observation. If the tip is
not kept in motion or if it is held too close, browning or
charring will occur, resulting in an unsatisfactory weld. If
the tip is held too far away or at an incorrect angle, an
uneven weld will occur. If the rod is pushed too hard into
the base material, it will stretch, resulting in a flat, highly
stressed weld, which will break if an additional weld is laid
over or abutting it or if it is subjected to routine environ-
mental stress.
Figure 3a. Good and Bad Flow Lines
8