Welding at TWS

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Hi, everyone! I hope you don't mind me setting up here.First, a little background info... I am a student at Tulsa Welding School in Tulsa, OK right now. As of the making of this topic, I have just begun Phase 3 - MIG and fluxcore. I have some experience in welding, albeit limited- I took "Intro to Welding" my senior year in high school, and pretty much only used 6010 (maybe 6011, I can't remember). My last memory from that time is doing 6G open root... but aside from what my instructor was telling me, I had no idea what the hell I was doing. I am making this topic to openly document my progress in welding as I go through the school- figured I might as well put it out in the open. Feel free to comment, give advice, or mark my topic for deletion. Right then, onto the next post!Keeping it down in the hood...literally!
Reply:Today is Day 1 of Phase 3. It was a little daunting today... Phase 3 has 6 positions we have to test out on- that's seven hours of welding time per position, not counting cutting/grinding/fitup/etc.I was quite nervous- this is the first time I've ever MIG welded before, and thus I'm still unfamiliar with the process. I made arrangements to watch the instructor perform a demonstration, and then... off to the races!Specifically, we set up some T-plates on 3/8" mild steel, I think? To start off with, we're doing 2F.The process is much different from the 7018s they've had me run the last six weeks. It's all... very alien to me. The welding gun is also heavier than the old stinger... I tire out fairly quickly. Supposedly, my gun angle is suffering for it (get lazy, and your gun starts drooping...)Puddle control seems more like using 6010, but it's still weird... it's drawing little semicircles across the length of the weld, while pulling the gun towards the end (just imitating what the instructor was doing). I still don't really know what to look for when making these circles... I read today after the fact that you're supposed to slow down enough to keep the wire in the puddle- I think I was traveling a bit fast today, as the arc would sputter and cough on me sometimes. It's a tad disorienting though, as the nozzle blocks my view of the front end of the puddle, so I haven't figured out yet how to put everything together...My instructor told me I have to straighten everything out (not being able to see where you're going distorts the line for me), and move more consistently to get rid of the undercut on the top. Keep the gun angle consistent to flatten things out...Well, guess I just gotta keep working at it.Right then, pictures.This is at 18.5 volts, a wire speed of 200 (I'm assuming IPM? but I wouldn't know.)The machine is a Lincoln Invertec v350-PRO.I don't know or can't remember the rest of the specifications. The first set of three is my first (or second, failed to mark the pictures!) try at it... the second set is my third or fourth. Attached ImagesLast edited by Drake Aldan; 10-26-2009 at 05:48 PM.Keeping it down in the hood...literally!
Reply:Second set.As a sidenote- apparently you can start with the wire touching the metal? Pulling the trigger completes the circuit... right?Because of my unfamiliarity with the process, and the fact that my auto-darkening helmet is currently out of commission, my starts were all weird because I was afraid of being randomly flashed.Apparently you don't get randomly flashed with MIG like you do stick... do you? Attached ImagesLast edited by Drake Aldan; 10-26-2009 at 05:51 PM.Keeping it down in the hood...literally!
Reply:When you make your circles make them quickly, like as fast as you can.  This keeps the entire puddle hotter and more fluid.  Another thing about circles make them as large as you want the bead to be.  Small circles in a wider weld can cause overlap/cold lap at the toes.  Something else I do is make the circles counterclockwive when traveling left to right and clockwise when going right to left seems to help with undercutting at times?To see better either stand slightly in front of or behind your gun to see the puddle better.As for the sputtering at the front of the puddle back off the WFS a little or mess around the the arc control that should smooth things out.What gas are you using?Good luck!
Reply:75% Argon, 25% Carbon Dioxide... I think.Keeping it down in the hood...literally!
Reply:If you not working to a specific procedure that is limiting your voltage you may want to run it around 20 or 21 with the appropriate WFS.  Hotter weld, smoother appearance and still in the short circuit mode.Not a big fan of ar co2 mixes, give me good old co2 for solid wire.
Reply:What's with all of the "I think" and "I wouldn't know"You were there, right?Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by EyesolatorSomething else I do is make the circles counterclockwive when traveling left to right and clockwise when going right to left seems to help with undercutting at times?To see better either stand slightly in front of or behind your gun to see the puddle better.
Reply:also i forgot to add when you get to the phase that lets you pick between high frequency or down hill do the down hill.... high frequency is super easy plus there no real challenge at that school
Reply:Never been a fan of circles....  I like more of a slight weave, more of a rock than a weave, and pushing.  Do you have to do it a certain way, or does the instructor just tell you to make a weld?  What size wire are you using?My name's not Jim....
Reply:The main thing to remember with mig is the greatest penetration will occur where the wire contacts the base metal or puddle.  The biggest danger with mig is a decent looking weld and no penetration.
Reply:Originally Posted by Broccoli1What's with all of the "I think" and "I wouldn't know"You were there, right?
Reply:Originally Posted by Drake AldanI'll have to take that with a grain of salt friend... people said MIG would be easy, and people said 1G would be easy, and neither of them were because I didn't get it perfect on the first try, or the second, or the fifth... I figure if this were so easy, people would be getting paid right now .
Reply:Yeah, I am probably going to do both. OJT is the name of the game anyway. A little bit of everything now, we'll get hardcore later...Well, I seem to have graded out on 2F finally... I got some tips in class yesterday and it seemed to smooth everything out. "Cool beans." Attached ImagesKeeping it down in the hood...literally!
Reply:Got started on 3F right away... It's a little weird, you run root and then cap and that's it, only two passes?!The settings are the same as 2F. Apparently I'm moving upwards too much, my stopping frequency needs to be higher.I think I can see what he means, now that I look at it...you think I should probably stop on one of those orbs halfway, or more than that?I ran out of wire on the last one. It was popping on me at the bottom, and then just- pfft! nothin'. Oh well. Attached ImagesKeeping it down in the hood...literally!
Reply:Before I roll over.My first one seems to look better than my third! I did the first try after watching my instructor's demo, and he said "just get wider"...I must have overcompensated... how wide should the stopping points be along the root?I'll have to ask him tomorrow... Attached ImagesKeeping it down in the hood...literally!
Reply:Aiyah... 11 tries overall! But I finally got it.No time to celebrate though, onto the next one... grooves, grooves...Open root... how do you do open root with such thin wire?! Questions, questions...I'm going in to cut beveled plate on Saturday... forty 4"x9", 3/8" plates I'll cut and grind (or at least, I will try, if my calculations are accurate.)It's really still not enough to last me the week, either... but I don't have enough storage capacity!Sheet metal is heavy... cutting and grinding is not very pleasant.  Attached ImagesKeeping it down in the hood...literally!
Reply:2G already. Can you believe it?I've not finished putting the pieces together yet. Weld's "too heavy", but that seems to be a matter of placement which I overlooked...we'll see if we can't make it work tomorrow! Attached ImagesKeeping it down in the hood...literally!
Reply:My instructor came by when I was welding this morning and gave me a few suggestions. Running the root pass became a little easier, but I still have a little trouble with it.In the latter part of today... I had an epiphany.My instructor had been doing two beads, all the way through. Two bead fill, two bead cap, maybe three bead cap. I had been trying to imitate him, and my caps kept coming out sloppy and droopy.I don't quite know where it came from- but for some reason, the diagram from the books popped into my head.First, run the root pass, then run two beads, then run three, then cap four. Run them skinny and small.It took me two tries, but the finished result struck me- this looked like the old 7018 1G I had done!It occurred to me later- a smaller puddle is easier to control than a larger one, especially out of position.Apparently my instructor, who has more experience than me, is able to control a larger puddle more efficiently than I can. Attempting to mimic him here was a mistake- I did not have the right tools to do so... so I had to diverge from the procedure he had showed me.I am glad things turned out the way they did, however. I feel as if I have regained some control, if even a little bit.Victory will... be in my hands soon enough! Attached ImagesKeeping it down in the hood...literally!
Reply:Yep, Each layer should have more passes than the last so they overlap.  With the exception of the cap.My name's not Jim....
Reply:Finally graded out on 2G today. Thank goodness!I'm getting kinda scared, actually. I'll push through, but everyone is behind. We're talking... five positions in five days!I think... we're gonna have to crank it up... Attached ImagesKeeping it down in the hood...literally!
Reply:3G... didn't test out today. I'm losin' it, man Constructing a good weld always seems to elude me... instead of me mastering the puddle, the puddle seems to be mastering me.I just don't know what I'm doing anymore. Though, I can't say that I ever did...I will attempt to fix this on Saturday. Attached ImagesKeeping it down in the hood...literally!
Reply:I managed to get some instruction today! There may be hope for me yet.But holy-moly, the fill and cap goes by faaaaaaaast! I can't keep my composure going that fast, at least not yet.Ahh, lumpy welds... I'll figure out how to make you flat one day! Attached ImagesKeeping it down in the hood...literally!
Reply:Try moving faster over the center of the weld when weaving in the cap, pause in your toe to let the puddle fill in then quick across the center. That should help level out your weld on the covers.Also, if you are cutting and preping your own coupons, any extra attention you give to your tourch work now will pay huge dividens in the future."Don't tell mom I'm a welder---She thinks I am a Piano Player in a Whore House!"
Reply:Aaand... fluxcore?!I don't ask the questions around here.Everything's still a bit shaky, but fluxcore seems... I dunno, smoother. Sure, it runs hotter and bubbles, but... the sound seems to have a calming effect. I don't know.Well, at least I have plates for days now! Attached ImagesKeeping it down in the hood...literally!The heat from fluxcore is just kicking my ***! Ouch!I managed to grade out on the weave... not so much on the stringer caps.I hope I can make it... Attached ImagesKeeping it down in the hood...literally!
Reply:Graded out on my last plate!!! woo!Good enough for my instructor, good enough for me.Monday it's back to stick... I hope 6010 treats me well after so long. Attached ImagesKeeping it down in the hood...literally!
Reply:2G. 6010. Reunited with the old mistress once again!Spend a year away from her, and she don't like you very much. We'll see if she won't warm up to me the next couple of days. Attached ImagesKeeping it down in the hood...literally!
Reply:All that time away from her and I'd forgotten... She doesn't like half-steppers.You have to push in deep, and penetrate all the way! It's the only method for satisfaction!But it's almost there... Almost! It's coming soon! Attached ImagesKeeping it down in the hood...literally!
Reply:Go too slow and she vomits out the back.I don't really have any good metaphors or innuendos for that. It's just ugly.Ahhhh... I mean, I used to do this! Have my skills really left me completely after a year? Ack!All I can do is keep my hood down, I suppose... Attached ImagesKeeping it down in the hood...literally!
Reply:Looks like you are doing pretty good esp with the weave dual shield. Maybe a little bit lumpy. looks like the tieins could blend together better. Looks like you are getting a little bit squirelly with the stick roots. I like to concentrate on keeping my toes even on both sides to keep my weld straight. It takes a little bit of a "space out" mind set to watch both toes at once but it works. Just ignore the rest of the world. The weld is all that matters. If' i'm whipping a lot I like to pick a good song on my ipod to help keep my rythem for me. Some older eve 6 has a good beat for welding. So does some of the new coldplay(**** off i know it's gay). reason being this. if your whip is just something you do unconciously(sp) it allows you to concentrate on other things. I notice on your SC mig welds there appears to be a lot of spatter. do you get to set your own machine yet or is the instructor doing it for you? I would suggest bumping your WFS up a bit until you get a constant buzzing sound. You shouldnt have to linger to fill your puddle with filler. Esp out of position. Set your WFS so you have to move just faster than you are comfertable with to create any kind of undercut. The exact point at which the puddle just fills in with no undercut is your desired speed for that wfs setting.Last edited by i4sillypwr; 11-20-2009 at 11:07 PM.
Reply:Do you mean watching the toes in that instant when you pull forward out of the puddle and into the keyhole? Shoving the rod back into the puddle turns everything blank- I've been going by feel, pretty much.I had to set my own WFS, but I opted to use the preset settings they had up on the wall, or what I gained from the instructors. I don't know enough about the process to control things like spatter (usually bumping up the WFS would make the machine run smoother, but the spatter would still be there).We're probably done with MIG though, so.Keeping it down in the hood...literally!
Reply:A week of no welding!I think I did pretty good for my first plate back. Attached ImagesKeeping it down in the hood...literally!
Reply:I left my amperage up by accident today when running a root. It... welded well!I am going back and checking with my instructor tomorrow. I'm gonna find out what to do, even if I have to ask a million questions and drag him to my booth... Attached ImagesKeeping it down in the hood...literally!
Reply:I had a familiar feeling today.It felt... like it used to back in Abilene, if only for a second.The instructor said... I made a lot of progress today.Slowly, but surely... Attached ImagesKeeping it down in the hood...literally!
Reply:Screwed up the tie-in... oh well.Instructor says my caps look real pretty. I wouldn't know Next is overhead! I can't even remember what it's like."Hot metal", maybe. Attached ImagesKeeping it down in the hood...literally!
Reply:Overhead is playing uncle with me... and it's winning...The following pictures compare my instructor's 4G, and... my 4G.Man, it looks like I've never held a stinger before. What's going on?! Attached ImagesKeeping it down in the hood...literally!
Reply:It's starting to look like I can weld with some dignity now!Man, I wish I could progress a little slower. Just when I get the hang of things we move on to the next position!  Attached ImagesKeeping it down in the hood...literally!
Reply:I need more hood time.Seriously. Attached ImagesKeeping it down in the hood...literally!
Reply:Ever since I started welding in high school, I carried with me this feeling... of not knowing what the hell I was doing.It's never went away. Next week is pipe already... *sigh* Attached ImagesKeeping it down in the hood...literally!
Reply:Pipe. Need I say more?I'm having trouble keeping everything flat, so my caps are coming out uneven, with low spots or undercut on the top. I'll have to study either bead sequencing or my own travel speed... Attached ImagesKeeping it down in the hood...literally!
Reply:I had an epiphany today.Old advice that isn't yelled out enough- but you have to learn to read the puddle.The puddle tells all. Amperage, arc length, rod angle, travel speed... by themselves aren't important. It's what they do to the puddle that is important!If you cannot see the puddle, you cannot weld. If your weld turned out bad, you were probably looking elsewhere, or thinking about something else, and not looking at the puddle.Everything makes sense now! I'm actually getting the feeling that I know what the hell I'm doing!Things just got real fun for me. Attached ImagesKeeping it down in the hood...literally!
Reply:It's been a while, hasn't it...I was supposed to come out rested from Christmas break but... getting snowed in just left me tired out!2G took me two days to get right again. I still ain't gonna be passing any bend-tests or x-rays by the looks of things, though.We have to move on to 5G now, and I'm not liking the way the logistics are going. I'll... do what I can, though.Figures that it's the mother of all welds, and I only get a few days to strike out on bell-hole.  Attached ImagesKeeping it down in the hood...literally!
Reply:Gettin' lumpy on the bottom. I probably look stupid when I start the overhead portion. haaah... I know it takes time, but the problem is I don't have any... Attached ImagesKeeping it down in the hood...literally!
Reply:Hey Drake,I'm enjoying the photos. Your welds aren't that bad for a beginner. Gotta warn you though, finding a job right out of school in the Tulsa area won't happen unless you know someone in the industry. So if you love it and don't mind having a 'regular' job till the market changes, then keep up the good work! If not, I'd get a refund man.~JoshLincoln Ranger 250- Kohler 23hpVictor SuperRange II torch03 Ram 3500
Reply:hang in there.  I remember when I was doing 6g on pipe.  I was leaving a ton of under cut on top of one side of the pipe on the hot pass.  My instructor came in my booth one mornig while I was doing a  hot pass, and yelled "go counter-clockwise silly."  After that, my hot passes came out great.I was there when the Apple brother's were instructors.Last edited by tortis; 12-30-2009 at 07:44 PM.
Reply:Thanks, Josh. I don't plan on staying in Tulsa, actually... I go where the work is, you know... that's the plan, anyway.... Apple brothers?Keeping it down in the hood...literally!
Reply:Aaah. Scrapin' by, really...Can't say you could call me a pipe welder for a while... Attached ImagesKeeping it down in the hood...literally!
Reply:It gets lumpy at the bottom because at the bottom I have a tendency to stick. Starting the arc is hard and when I do start it either sticks, or I get it going and then get too close and it shorts. Welding over these lumps just... makes everything lumpy.I normally don't break out the grinder when filling and capping... but today, I had just the last half of the pipe to cap. I tried to start and it just kept sticking, leaving this lump instead of a cap...I got mad, broke the tack holding the pipe in place, flipped it over, changed out the wire wheel to the grinding wheel, and took out my anger on that lump.... It turned out better. I guess I'll be breaking out the grinding wheel more often than usual from now on. Attached ImagesKeeping it down in the hood...literally!
Reply:The weld you see before you... got me Top One, apparently. I mean, to me, there was a million and one things I could've done better, but I guess that's off the record now. Oh well.Funny thing. I've been combating my sticking problem by intentionally sticking the rod first and then breaking that(by gently wiggling + waiting for the tip to heat up) to start the arc.I wonder if this habit's gonna be detrimental one day.I hope tigging is going to be like I think it will be. Attached ImagesKeeping it down in the hood...literally!