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This is the second one of these jobs.  40 pieces about a 1' X1" square ring welded to the 5/8"? base.   Look at the top of the plate, there is an X so I know which side is up.This time I ended up using .045 wire pulsed spray in a 400 amp bernard knock off by paraweld.  92/8 argon/Co2   250 inches per minute of wire speed.  The meter said average amps 180.  When was  using .030 it said average 130 and with .035 it said 150.  I had the heavy duty tip and gas cone on a 200 amp tweeco.  It just got too hot and would bind up the wire,  The gas cone was glowing and the contact tip would bend.After I switched to the 400 amp with a large contact tip, things went right along.  A single pass about 30" long 5/16" bead.  I went back and forth staying at the front of the puddle.   positioner was as slow as it would go with out stopping.  I think it took about 10 minutes go  around after tacking.Prep material   Its A572 with one heck  of a bark  (millscale) on it.  3 tachs.Material flow.  Highest on the forklift, then positioner then horses.   As far as I know these parts were all laser cut.  Skid of completed ones on the floor.Settings   Pulsed spray .045 wire, "argon Blends"  (up to 20% Co2 or 5% oxygen)  251 inches per minute wireSexual close up next post  Last edited by Fred Sanford; 01-12-2011 at 07:59 PM.
Reply:MachinedDavid RLast edited by Fred Sanford; 01-12-2011 at 07:58 PM.
Reply:I think you got the right combination. That's awesome. Do you guys also do the machining?
Reply:Thank you, I just make sparks.
Reply:Hmmmm? Something FISHYhttp://weldingweb.com/vbb/showthread.php?t=47486You have to learn the rules of the game. And then you have to play better than anyone else. Albert Einstein
Reply:Originally Posted by jreynoldsweldingHmmmm? Something FISHYhttp://weldingweb.com/vbb/showthread.php?t=47486
Reply:Same shop, same forklift, same yellow table, same positioner, same grey cabinet.  Did David hire some help?same shop built saw horses too.Last edited by Boostinjdm; 01-12-2011 at 10:42 PM.My name's not Jim....
Reply:boostin lol look at my post on davids thread
Reply:How bad did these warp compared to the other batch David? Did the larger wire make it better or worse?.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:Welds look great obviously, but I'm curious about the settings you listed.  10min for 30" of weld?  That's outrageous....  That's 20 seconds per inch.Also on thick material like that 250ipm seems very low, you could easily run higher wire and travel speeds, still get your 5/16 fillet and GREATLY reduce your heat input.  Just some food for thought.Have we all gone mad?
Reply:Originally Posted by jreynoldsweldingHmmmm? Something FISHYhttp://weldingweb.com/vbb/showthread.php?t=47486
Reply:Absolutely no doubt about it!  This is the same shop!  Check the cabinets, the paint job, the positioner, the forklift, the conduit and the block wall. BUSTED!"The man of great wealth owes a peculiar obligation to the State, because he derives special advantages from the mere existence of government."  Teddy RooseveltAmerican by birth, Union by choice!  Boilermakers # 60America is a Union.
Reply:He's mentioned in a post a while back that they are the same person.
Reply:David R was a moderator on this site.  David got tired of some sales people that have no integrity so  I no longer wanted to be associated with those said sales men.  Fred Sanford is born.YUP its the same job.  Read the specs closer.  The .030 wire was run at 400 Inches per minute on pulsed spray.  The .045 wire was run at 250 inches per minute.  .045 warped a little more, but the customer is OK with that.  He has to straighten them in a press anyhow.  I sure could weld faster with the .045 wire.  If you look even closer to the last batch in the David R thread, you will also see the mark that shows the top.   My customer put it on the wrong side.  I welded 40 rings on the wrong side and got paid for it.  I then welded 10 more rings on the other side for a test.  (those were free)So far as this morning I have welded 70 rings on.   Last night I loaded up those 20 and unloaded 20 more.  David R
Reply:Originally Posted by sn0border88Welds look great obviously, but I'm curious about the settings you listed.  10min for 30" of weld?  That's outrageous....  That's 20 seconds per inch.Also on thick material like that 250ipm seems very low, you could easily run higher wire and travel speeds, still get your 5/16 fillet and GREATLY reduce your heat input.  Just some food for thought.
Reply:Hi David,I've just played with the pulse on thicker stuff with my PM300 and really never liked it (it's a soft pulse more tuned to holding a puddle in thin stuff I think). The 5/16' fillet would be tough with hard wire in spray without serious pre-heat. The .045 will weld at 250 in short arc very well without smoking torches that bad and maybe get a little better travel speed. I guess you're in that zone where any number of things can work well.The scale on roller quenched plates is a PITA! It's tough to needle scale and tough when grinding. I usually reach for the 5 inch 7000rpm and a 4" norton charger or norzon type 11 rock for that (aluminum oxide just loads and burns). I have 5" rocks for the 7" grinder for when I'm pissed, but it's an arm breaker...Being up on the list for a going shop is a very very good thing.Looks nice, I don't care what you call yourself, thanks for posting.(edit) I should add I don't understand the plate not being shot blasted? Is this going to be painted? The shop may get a hard lesson if it's a sub let job and they missed the cleaning specs...MattLast edited by Matt_Maguire; 01-13-2011 at 09:48 AM.