Welding Wrought Iron

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Hello all, I'm new in here, and vaguely at welding, a newbie.  What are your guys thoughts on the best process/welder type for welding wrought iron bar stock, appx. 1/2" square bars.  I need really good clean welds, with minimal slag blown all over the part.  Any help here would be appreciated.John.
Reply:Real wrought iron?As in low carbon, with silica inclusions, last made in the 1970's?If so, there were several grades of wrought iron, with the lowest grade having very definite grain, and large irregular silica inclusions. Then, there were better and better grades, the best of which were smooth, pure, and not lumpy at all.Forge welding is usually considered best for this- heat and beat, so to speak.Next is usually gas (oxy-acetylene). It can be electric welded, but how well it works really depends on the quality of the wrought iron. High quality stuff, like the pipe the swedes were making up thru the 70's, should tig weld quite nicely.Wagon wheels from 1880, on the other hand, are gonna be tough.You might ask over at www.anvilfire.com, in the guru's den- a lot of blacksmiths there with a LOT of experience with wrought iron.If, on the other hand, you are using wrought iron as a generic term for mild steel ornamental ironwork, then any welding process will work just fine.
Reply:Yes, it's ornamental iron for balusters in a staircase.  It's nice to get that thorough of an answer from someone.  I take it you're quite the metalurgist.
Reply:Not exactly a metalurgist, but I have burnt up my share of all kinds of metal.I do a fair amount of forging.Anyway, me, I prefer tig welding 1/2" square mild steel into ornamental iron- its clean, good looking, and requires no cleanup.But you can stick weld it just fine, with a smallish rod- 3/32,  maybe.Or you can mig it.
Reply:Jolafson,Are you sure you have wrought Iron or  is it just hot rolled steel?  I realize you said "yes",  however I was curious to know if you were actually making the distinction that of which Ries was speaking.Many times people refer to any to ornamental metalwork as wrought iron.I have never made pretty welds in wrought Iron. Just seems like there is always stuff boiling through the weld.  I only occassionally come across wrought iron for repairs.
Reply:First off welcome to the forum! Ok I take it you dont have a welder? I MIG weld all mine. TIG looks the best and if a customer request it I do it but not as a rule. I would not recomend flux core wire it will make a lot more clean up for you. Use something like er-70 wire with 75/25 welding mix (argon / co2). It also helps to get some anti spatter spray. I get mine from Home Depot it is an arosol can like paint. Spray all the metal around the weld area and any were spatter will land also use a little on your nozzle it help to keep it clean. I use .035 wire but I would recomend to you to use .023 and a small MIG like a 140 amp unit would be great. I weld all 4 sides of the bar and grind down the side that is seen and be carfull not to grind the weld off leave a little hump if you dont it will have a tiny crack and will rust. The biggest thing I found here to make a nice rail or burgler bars is to get a twisted wire wheel and brush the crap out of the part befor you paint. I try to remove most if not all mill scale. If you dont the traped moisture will cause rust below the paint. Hope this helps if not I can provide more details. Good luck and keep us posted. Steel Thunder Welding LLC. St. Thomas VI USAMM350PBOBCAT 3MAXSTAR 150 STH375 EXTREME PLASMA6.5 HP COMPRESORDEWALT 18, 24, AND 36 VOLTO/A TORCH SETAND SO MUCH MORE I DONT REMEMBERALL IN MY 2005 2500HD EXTENDED CAB L/B
Reply:Learn to weld first. If you want it to look good leave it to a pro. If you must do it yourself get ready to spend lot's of time and money. The machine won't make the nice smooth welds for you, that's a skill thing. If you don't even know what type machine you need then you don't have the skills it takes to build these things. You aren't by any chance in New Orleans are you.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:ive been doing onamental iron work for 16 yrs now and the best way i have found is mig  aka  wire feed   i use a millermatic 35  and it lays in a nice clean bead but any wire feed will do you can use rod but then you have more clean up tig looks nice but is very time consuming if u have any more questions give me a ring 307 660 7920 or drop me a note [email protected]
Reply:Originally Posted by jolafsonYes, it's ornamental iron for balusters in a staircase.  It's nice to get that thorough of an answer from someone.  I take it you're quite the metalurgist.
Reply:i think he is just using mild steel to make what we now days call wrought iron or ornamental iron