first frame fab

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Hello, Been a lurker for a while trying to learn all I can.  Been machining for years and did some tig and mig 10+ years ago, but getting back into welding now.  I manage production for a small manufacturer and we normally outsource our welding to a great local weldor, but recently to cut costs I have been taking some of the stick and mig over myself.  Nothing structural or critical.  Mostly welding on small mounting tabs and such to frames he fabs.  Up to now super glue would have worked for most of it.Finally felt i had enough mig practice to take on a low stress frame myself for a 1 off custom job.  Got started today on the layout and welding.  Let me know what you think.  Seems to be holding square pretty well after i flexed the heck out of a welding cart attempt.  Inside and outside corners welded, top and bottom still to goMM140 AutoSet.  Maxed out amps;  0.030; 15cfh 75/25; around 275 ipmLast edited by Drooopy; 10-18-2013 at 05:13 PM.
Reply:Almost looks like you are spotting the welds (laying stacked tacks instead of continuous beads).  Is that what you are doing?--Wintermute"No man's knowledge here can go beyond his experience." - John Lockewww.improvised-engineering.comManufacturer Agnostic:Blood----------Sweat---------Tears----|------------------|----------------|----Lincoln Red, Miller Blue, Esab Yellow
Reply:More like a move and pause but similar effect.   Continuous wire run though.  I am able to keep an overall straighter bead this way.  I struggle with straight line steady pulls.  maybe i should tighten up the movements?
Reply:Mig down hill I like to make a z pattern pausing briefly on each side to acquire wetting effect and don't go slow through the middle
Reply:It stinks, but keep at it. I am not being a meathead to you at all, just being honest. I never give people false positives,it really stinks. Keep at it tho and in short time you'll realize I wasn't such a buffoon! Tighten it up, focus on your arc length, gun angle, travel speed and reading your puddle. Waste material, gas and money and never practice on a job or project. I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I am happy to take constructive criticism,  but I am gonna need a little more input on what is inadequate.  The look? The penetration?  For info, total weight of the mounted equipment will be about 1300lb with most of it in direct compression of steel members. I did some destructive testing before I started the actual project.  Penetration is  definitely not full depth, but more than adequate for the application. No porosity. Is there something I am missing that will fail?In the z pattern, is there a true z as in horizontal cross the angle down or more of a zig zag consistant down angle with each movement? Thanks for the comments. Sent from my SPH-L900 using TapatalkMultimatic 200Ellis 1800Haberle S225 9" cold sawMM 300;  Spoolmate 30A w/ WC-24TB 302GDynasty 280 DX Tigrunner
Reply:Originally Posted by weldermikeIt stinks, but keep at it. I am not being a meathead to you at all, just being honest. I never give people false positives,it really stinks. Keep at it tho and in short time you'll realize I wasn't such a buffoon! Tighten it up, focus on your arc length, gun angle, travel speed and reading your puddle. Waste material, gas and money and never practice on a job or project.
Reply:Spent some time working my technique.  Still have a lot of work to do on feed speed consistency and haven't tried vertical up yet, but I think I am understanding what you are saying.  Let me know if I am still totally missing the point. Also a cut away on penetration on one of the original welds.  I know this is sufficient for this application as it is very low stress.  As I said, MM140 maxed out 2x2x0.120 wall.  Welder is on dedicated 30A 120 circuit with 20' total 10ga panel to plug.  Welding 30sec then 10 min off.
Reply:you're getting it ,,, keep practicing ,, you'll be there before you know it
Reply:you're pushing that machine to is max running it on 1/8" stock. If you look closely you can still see the line on the base metal for the bottom plate which means it didn't penetrate enough. Also, with 1/8" metal you should be getting penetration all the way through the material. I'd say it's time to upgrade to a 220 machine. Especially if you're using it for this on a regular basis.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:That job is too big for the machine you're usingMillermatic 210 & 300Miller 330 a/bp w/Miller coolmate 3Lincoln 225 ac/dc buzz box200amp Hobart 16hp portable welderCarbon arc torch, oxy/acy, plasma cutterCNC plasma table
Reply:Originally Posted by Drooopy Welding 30sec then 10 min off.
Reply:off as in not welding, not off as in power off.  I let the fan run for at least 2 hours after I quit welding. As far as production with this machine, this is a prototype frame.  Only reason I am building it is that it is completely impractical to keep a weldor in my shop for the 2 weeks of weld/fit up/ cut - repeat that a new product takes.  I have full 3D designs of every last detail, but tolerances can be a b***h and I have never had a prototype like this go together without this process.  Everything gets blueprinted at the end.  Next and all subsequent frames get built by a pro and me and my guys go back to assembly as usual.   Customer gets custom at a standard price for letting us use them as a test.On this particular job, FEA shows I could have 1/4" of weld on each side of the squares and the frame will still hold.Last edited by Drooopy; 10-21-2013 at 12:08 PM.
Reply:Ok cool, just checking Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.