Operating Instructions and Parts Manual
10
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weld angle
Weld angle is the angle at which the nozzle is held during
the welding process. Using the correct angle ensures proper
penetration and bead formation. As different welding positions
and weld joints become necessary, nozzle angle becomes an
increasingly important factor in obtaining a satisfactory weld.
Weld angle involves two positions - travel angle and work angle.
Travel angle is the angle in the line of welding and may
vary from 5º to 45º from the vertical, depending on welding
conditions.
Work angle is the angle from horizontal, measured at right
angles to the line of welding. For most applications, a 45º travel
angle and 45º work angle is sufficient. For specific applications,
consult an arc welding handbook.
wire speed
The wire speed is controlled by the knob on the front panel. The
speed needs to be “tuned” to the rate at which the wire is being
melted in the arc. Tuning is one of the most critical functions of
wire feed welding. Tuning should be performed on a scrap piece
of metal the same type and thickness as that to be welded.
Begin welding with one hand “dragging” the torch nozzle across
the scrap piece while adjusting the wire speed with the other
hand. Too slow of speed will cause sputtering and the wire will
burn up into the contact tip. Too fast a speed will also cause
a sputtering sound and the wire will push into the plate before
melting. A smooth buzzing sound indicates the wire speed is
properly tuned. Repeat the tuning procedure each time there is
a change in heat setting, wire diameter or type, or work piece
material type or thickness. For Aluminum, wire speed is typically
set higher (7-9 speed range).
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
Figure 8). 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.
eleCtrode eXtension
Electrode extension (or electrode stick-out) is the distance
between the end of the contact tip and and the end of the
welding wire. The recommended electrode extension is from
1/4 in to 1/2 in (6 mm to 13 mm). If the electrode extension is
Welding Guidelines (Continued)
5° - 45°
5° - 45°
WORk ANGLE
TRAvEL ANGLE
Figure 9 - Weld Angle
too long, welding current will be reduced and the bead will be
high and narrow with less penetration.
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 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 60º angle. Remember to remove the slag before
each pass for the FCAW process.
Cover
Filler
Root
Figure 10 - Weld Passes
Figure 11 - Multiple Weld Passes
