Ok, Answer me THIS.... ROFLMAO

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Now, I like bubbles in my beer, but not in my weldsJust finished the modifications on the the third of three axles.  This problem cropped up at the end of the second axle, and continued today on the third one.5/32 7018AC run at 175amps.Pic one....... First fill pass after root pass.  Root pass was made with 1/8 rod, pass in pic was made with 5/32 rod.  Not a pretty sightPic two.........  GRIND THAT MESS OUT!!!!!!!!!!!!Pic three....... Let's give it another try with another rod outta the same batch.  NO SOAPPic four..... Give the offending rods the deep six, and go back to 1/8 rod.  SMOOOOTHPic five.........  3500lbs of filler rod later, a nice finish to a shaky beginning.  Bubba didn't get no bubblesOne more pic to follow Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:We don't need no stinkin' preheatThe ol' pup didn't cold nose this one while it was coolin' . Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:After considering everything under the sun, y'all know me, no cosmic solutions came to mindI just figure it was a bad batch of rods................."Any day above ground is a good day"http://www.farmersamm.com/
Reply:I'm no 7018(AC) expert but bad rod (moisture) would be my guess.  I believe you said recently it's been raining alot there lately?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Yeah Duane, but the 1/8 is the same age as the larger rod, and opened at about the same time.  It's a mystery to me.I did think about exactly what you mentioned, and I'm gonna put the big rods in the oven at 250 for 2 hours, and see how they come out.I wonder if the larger rod, because it has more flux coating maybe picks up moisture better?????"Any day above ground is a good day"http://www.farmersamm.com/
Reply:I gotta agree - I think a moisture problem is to blame.  Couple years ago, I opened a brand new box of 1/8" 7018.  First rod wouldn't even strike an arc.  Second struck but then promptly stuck.  3rd and 4th were all the same story too.  I ended up throwing the entire box out - couldn't use any of them and I blamed it on moisture. Sam, you should go in the plow axle repair business - you're getting to be an expert at them!!
Reply:That's interesting to say the least Sam.Check the paperwork though - I think 7018 wants more BTUs than that doesn't it?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Well, I'm running the 1/8 at 135amps AC, and the 5/32 at 175amps AC.The DC side of my machine tops out at 125amps DC, and I didn't feel that was enough heat for the thick round stock, so I switched to an AC rod.I need to take the time to get that Ranger going.  Got the leads sitting in the yard.At least that will answer the question about duty cycle, and machine capacity, and lead capacity on the little crackerbox.From what I've read, insufficient heat in the puddle will cause surface bubbles.  Also a short arc will do the same.It might be that although my machine is set at 175amps, I'm not really getting 175 at the stinger.I found by long arcing the rod, it ran better.  But I worry about penetration when I hold a long arc.I get into all this weird stuff  Somebody on the planet must have the same problems occassionally"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by Road WarriorI gotta agree - I think a moisture problem is to blame.  Couple years ago, I opened a brand new box of 1/8" 7018.  First rod wouldn't even strike an arc.  Second struck but then promptly stuck.  3rd and 4th were all the same story too.  I ended up throwing the entire box out - couldn't use any of them and I blamed it on moisture. Sam, you should go in the plow axle repair business - you're getting to be an expert at them!!
Reply:Originally Posted by farmersammAnd ya know.........ya gotta wonder about the boxes.  They're shrink wrapped.  I don't know if a corner was torn or what.At least the DC Excalibur comes in a SEALED tin can
Reply:Originally Posted by farmersammWell, I'm running the 1/8 at 135amps AC, and the 5/32 at 175amps AC.The DC side of my machine tops out at 125amps DC, and I didn't feel that was enough heat for the thick round stock, so I switched to an AC rod.I need to take the time to get that Ranger going.  Got the leads sitting in the yard.At least that will answer the question about duty cycle, and machine capacity, and lead capacity on the little crackerbox.From what I've read, insufficient heat in the puddle will cause surface bubbles.  Also a short arc will do the same.It might be that although my machine is set at 175amps, I'm not really getting 175 at the stinger.I found by long arcing the rod, it ran better.  But I worry about penetration when I hold a long arc.I get into all this weird stuff  Somebody on the planet must have the same problems occassionally
Reply:Originally Posted by farmersamm  Somebody on the planet must have the same problems occassionally
Reply:BTW...........................  FOR YOU POSITIONER FANS...........THIS GUY WASN'T THE RIGHT SHAPE TO MOUNT ON A POSITIONERSo it was bevel, and glue Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by duaneb55I meant when you cook 'em in the oven.
Reply:Originally Posted by farmersammAnd ya know.........ya gotta wonder about the boxes.  They're shrink wrapped.  I don't know if a corner was torn or what.At least the DC Excalibur comes in a SEALED tin can
Reply:Originally Posted by farmersammFor non x-ray, the bible says you can get away with a little less heat.  More like medium rare I guess
Reply:Originally Posted by Road WarriorNope, you're the first one I've ever heard of having trouble like this.  Seems to me like you must be living in a geographical oddity!!
Reply:I'm tellin' ya Duane, I really like the 7018, but it's like an Italian race car.  Finicky."Any day above ground is a good day"http://www.farmersamm.com/
Reply:You'll get porosity like that in the wind with LH, too. Not getting the same porosity using the 1/8 though, it's probably moisture. We were told years ago that if the wind exceeds 7 mph, LH could not be used w/o a windbreak. I was working at a chemical plant in Pasedena TX at the time and we had to use scaffolding with fire blankets for skin as a wind break around each of the welds. We also had the little rod ovens that plugged into the machine and kept the LH dry. Lots of humidity around the Houston area. Only when the last tree has died and the last river has been poisoned and the last fish has been caught will we realize we cannot eat money.                                         -Cree Indian ProverbSA 200 LincolnVictor Torches
Reply:Originally Posted by farmersammBTW...........................  FOR YOU POSITIONER FANS...........THIS GUY WASN'T THE RIGHT SHAPE TO MOUNT ON A POSITIONERSo it was bevel, and glue
Reply:On oven drying electrodes......rod ovens were/are a common thing in the shipyards. When I was there it was a common thing to see beenie weenies and other stuff in these ovens being warmed up for lunch. Well after a few cans blowing up and ruining a lot of wire, this practice was outlawed. Management had the safety dept. send out a sheet saying that there were toxic fumes given off during the drying and it was not safe to eat food warmed up in that environment. Not sure if that was true or just an excuse to scare guys out of doing it, but you may wanna think twice about using your wife's kitchen oven for re-drying electrodes.maniak
Reply:So I just have to get my nose in here lol.  Many E 7018 rods have trouble at start up with porosity.  It varies between brands.  The worst I encountered was an AC version of 7018.  A run off or rather a run on tab would have been a help in this case.  Strike up the arc on the tab then run the arc through the joint.  The tab would not have to be very big.  Something like a piece of 1/4 inch even as small as 1 by 1 inch would be enough to get started on.  From what I can see the porosity is in the first half of the weld.  Once the electrode is hot and running things are sweet.
Reply:Might have been some dross left on there from the OA cut, too.
Reply:Having to long arc your rod tells me you need to up the amperage. And 7018 is a short arc rod.What was said about some brands of 7018 having porosity at the start is true. Some brands are much worse than others.
Reply:Originally Posted by farmersammWe don't need no stinkin' preheatThe ol' pup didn't cold nose this one while it was coolin' .Originally Posted by farmersammFrom what I've read, insufficient heat in the puddle will cause surface bubbles.  Also a short arc will do the same.I found by long arcing the rod, it ran better.  But I worry about penetration when I hold a long arc.
Reply:Problem partially solved (I think)Cooked the rods, then held them in a portable oven while outside.  Humidity still running very high here.  Only can work between showers.First pic........5/32 7018AC.  Little bit of porosity at start and finish.  Read a good thing on Lincoln's site about startup porosity, will try to develop the technique.  Long arc at start to get a bit of metal dripping off rod and establish a hot puddle, then go back to a regular short arc to finish the weld.Second, and Third pics.......... Never had the 1/8 run so nice.  Taking into consideration it's a AC rod.  The DC rods run better hands down, but my little machine doesn't have the power to put out the amps above 125DC.  I gotta get the Ranger goin.  Pic Four.........  too much money for so little Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:looks like your issue was mostly moisture related, a little arc strike technique, and possibly dirty, humid base metal. drop the work angle down a bit to equal out the legs on those fillets. don't want to long arc those 7018's much. especially on your starts.. it will give you porosity. only enough length so it doesn't stick while the arc stabilizes.some causes of porosity i forgot to mention.. too fast travel speed, too aggressive travel angle, and too much current. don't let the rod fingernail. Attached ImagesLast edited by loudnproud; 05-15-2009 at 11:08 PM.