Plug welds

admin

Plug welds 5/1618 gauge0.23/CO2 26-30psie formation and sweeping left to right.I think I'm moving too fast, but also deal with hand/arm tremors. Last time I welded was 30 years ago. I warped my practice coupons but can make more, still I think I need to work slower. Practicing to get better at plug welding before actually welding in cab plates and rocker panels for my truck.From top to bottom~54A,16.8+2V~55A,17.2+4V~56A,18.2+4VIncrease Amperage? Any other suggestions?


Last edited by bandaids; 1 Day Ago at 02:41 PM.
Reply:when i was in college welding, there were guys doing "i-car" certs.    i didnt pay much attention, as it wasnt my interest.    but to my memeory, there were plug welds , then they'd rip the two pieces of sheetmetal  apart to examine the way it tore, which determined wether they passed the test or not.      might give 75/25 gas a whirl.    u might try some destructive testing like that, and see what u thinkLast edited by 123weld; 1 Day Ago at 05:03 PM.
Reply:

Originally Posted by bandaids

Plug welds 5/1618 gauge0.23/CO2 26-30psie formation and sweeping left to right.I think I'm moving too fast, but also deal with hand/arm tremors. Last time I welded was 30 years ago. I warped my practice coupons but can make more, still I think I need to work slower. Practicing to get better at plug welding before actually welding in cab plates and rocker panels for my truck.From top to bottom~54A,16.8+2V~55A,17.2+4V~56A,18.2+4VIncrease Amperage? Any other suggestions?



Reply:The CO2 gas is hotter and has deeper penetrating qualities.  I'd recommend 75/25, if possible.  For doing a plug weld, I would begin in the center and spiral out wards.We've done so much, for so long, with so little. Were now qualified to do anything with nothing !
Reply:I done plugs welds, first with stick E6013 till 1980 then E71T-1 with CO2.Most was 26 to 18 gauge on to plate. The fluxcore was very fast and easy. Dave

Originally Posted by bandaids

Plug welds 5/1618 gauge0.23/CO2 26-30psie formation and sweeping left to right.I think I'm moving too fast, but also deal with hand/arm tremors. Last time I welded was 30 years ago. I warped my practice coupons but can make more, still I think I need to work slower. Practicing to get better at plug welding before actually welding in cab plates and rocker panels for my truck.From top to bottom~54A,16.8+2V~55A,17.2+4V~56A,18.2+4VIncrease Amperage? Any other suggestions?



Reply:These seem to be much better, though I've read that increasing amperage to the point of burn through is where it is at. I haven't gone that hot yet. I'll have to make up more sample coupons. To clarify the "e formation" (some called it that) it's more of a circle starting from the center and 360 and back to center. I don't know what others call it, though from the examples I viewed from veteran welders they referenced e formation which made sense, if they mentioned azimuthal most would be scratching their heads. I have been making a single pass around the flange back to center, watched some videos where others are moving fast and making multiple spirals where others just made a single pass, is this preference or what is the proper way to complete a plug/rosette?  I've also watched some videos where you can visual see a stack of weld on the back of the sample coupon. I see very little on mine though from what I understand the penetration that matters is around the flange of the plug/rosette. These individuals never expanded on the very thin "black" ring that forms on the back side of the coupon which is between the weld and the shiny/polished ring (from the center out). I'm sure some of you will know what I'm referencing, it's a very difficult to see. I know all machines are different, even exact models. Though I think the welds ought to be relatively similar despite the amperage of each machine. 75/25, I wish I had the funds. Though from I hear from all bodywork it's C02 and the only difference is spatter.I am using MIG/CO2, 0.023 solid wire which is recommended. not stick.18ga on 18ga in these sample couponsAmperages are from bottom to top in photo, welding from right to left.68A, 17.6+1V3x 45∠68A, 18.4(17.6)+3V3x 45∠72A, 18.0+0V2x 45∠ sides1x 90∠ middle84A, 18.9(18.5)-1Vtop far right two 45∠ and 90∠84A, 19.3(18.5)+1Vtop far left at 90∠The last two that I welded top left two seem to be nicer. Welding at a 90∠ seems to allow me to follow the flange better, not sure if this is preferred over 45. I do have more build up with 45 over 90.Also that eastwood plugweld nozzle tip is a piece of junk, it's more for 3/16 plugs and not the common 3/8 and 5/16 plugs.



Last edited by bandaids; 9 Hours Ago at 05:51 PM.
Reply:after grinding


Reply:Reduce your hole size.Last edited by milomilo; 7 Hours Ago at 08:25 PM.ChrisAuction Addict
Reply:Used to do a considerable amount of plug welds.Like said earlier...............start at the outside, and let the puddle wash into the adjacent metal.  Don't try to place heat in the perimeter, just let the puddle wash into it.Whether you decide to fill in the center of the plug weld is a matter of preference, or according to the WP.  You do not need to fill the center.  The working part of the weld is around the perimeter, where it joins the adjacent metal.455Dan makes a nice weld, and fills the center.  As good a way as any.