cart welds

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Hi Everyone,I figured I would take some pictures of some welds I am doing at work. They are on some carts that look like engine stands.Material is 2.5 and 3" square 1/4 wall steel. Ground clean.Miller maxstar 200 maxed out.Grade 5 argon (Because I'm the only guy on bottles and they said ok) The other 15 guys are on a manifold from liquid tank.HP20 torchCoolmate 4 cooler3/32 ceriated tungGas lenseER 70S-2 1/16 WIREI'm Using pulse just to make it interesting.5 PPS70%ON TIME40% Background currentMachine on 200 and pedal flooredWhen the pulse comes up I ad wire then on the low pulse I move I never let off the pedal until trail off time.Let me know what you think and fire away the questions. Attached Images
Reply:How do you get awesome colors on mild steel? Looks great!Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Thanks,The pulsing of the arc reduces the overall energy put into the peice but you still get good pen with the long peak pulse. I am in a small weld booth surrounded by curtians that helps too. The gas lense and ultra pure gas help alot too.
Reply:Looks like silicon bronze as wellSome blue machinesSome red machineslots of heavy steel
Reply:why so small a wire in 1/4 steel at 200 amps? you must be feeding like crazy..nice flat bead..id say work on the corners, come around a little further ..
Reply:Weldbead,I will post pics tomorrow of the huge gaps at the corners before welding. I basically fill the hole then wash over it. The small wire is all we have because we weld stainless 99% of the time. These carts are a one time build for the production line. But I was also not happy with the wrap around. I will also post pics of the next one with a better approach.
Reply:Sounds like you're having to weld really slow due to the undersized machine. I'd definitely turn the pulse off and actually get some heat when you need it. The stacked dimes look is easily achieved by dabbing the filler of appropriate size (probably 1/16" - 3/32").Welding/Fab Pics: www.UtahWeld.com
Reply:The colours can be achieve without gas lens or purging. This picture was done using .045" ER70-S2 wire and a #6 cup. Not sure on amperage, my machine is always set on max and just go with the pedal. My gas is normally in between the 10-15 cfm range.Properly cleaning the parts is one big thing to begin with. The second thing, is that I find S2 wire to tend to colour more than S6 wire.
Reply:That looks great and very consistent looking weld.Good Luck and Never Give UpAWS MemberLincoln Idealarc 250 AC/DCHobart Beta Mig 251Hypertherm Powermax 45Lincoln WeldanPower D10 250 ProMilwaukee PortabandEllis BandsawMiller AEAD 200LE
Reply:Hi Everyone,Took a couple of pics of the improved fitup. I am machining all of the parts so I can get whatever fit I want. And a pic of the bearing head weld.MikeGyver, You are correct about the heat. The only reason I am using pulse is to make it more interesting. There are no welding specs for this and they are so over-engineered that I could put 1/2" tacks on all joints and they would hold. Attached Images
Reply:I like it. I never used pulse, but I am about to have to learn.Millermatic 211PowerPlasma 50s
Reply:Fit up is key, and yours is great CUDA! And no matter what your method is your welds look dyanamite! Nice work I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:You might want to think about simply putting a heavy tack at the corners before setting the upper tubes on to help fill that area. That way you can almost run a small fillet to fill in the corner from the top. If time is more important, then I'd probably just do what you are currently doing..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:DSW That is exactly what I am going to do on the next one. I will post pics monday of the results.225,The pulse is like built in rythm but, you need to get in time with the machine. I turned up the peak on time to get better wetting and, it makes you think. I have been doing this a long time and it is always good to experiment if the job allows. You never know what you will learn.
Reply:One thing I'll note about the fishmouth in the first pic of post #10. The taper going to a knife edge might not allow for as strong a joint as if the sharp edge was cut back and the "lap" joint was filled using filler.Welding/Fab Pics: www.UtahWeld.com
Reply:man, those sure are pretty welds. Originally Posted by GambleHow do you get awesome colors on mild steel? Looks great!
Reply:DSW,I welded one filling the corners first. It is the first pic, Worked much better.MikeGyver,The second pic shows the fishmouth with a land. And the third shows it welded using 180A no pulse.Then I show a pic of the pivot point that allows the carts to fold for storage and one of a finished frame.Thanks for looking. Attached Images
Reply:So let me get this straight...it's an engine stand, but it's not an engine stand?....Trying to figure out what exactly you would use it for....   Looks great though!Miller Dynasty 200Millermatic 211Instagram?.... find me @ WELD_MEDIC