Failed test

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I received my 3G &4G test results today and I failed! I really thought I had it in the bag. But the results can't be argued with. I had a stretch of incomplete fusion on the 3G and On the 4G I had a porosity too close to an inclusion. All inclusions occurred at my tie-ins on the cap pass. I'll have to work harder on it and take it again. Looks like the incomplete fusion  was on a fill pass. I remember my instructor mentioning my fill stringer was a bit proud and to be sure to burn it out good. Obviously I didn't.  Well my hats off to you guys that have passed these tests. It was close but no cigar for me this go around. Gizzmo
Reply:If this is stick, that you are talking about which it seems it is, when working the restarts, you have to start ahead of the last part of the crater, for me about 3/4 to 1" and drag it back as it heats up the rod, but doesn't transfer the metal.  I always pause just a a fraction of a second to burn in the tie in.  Sounds like you might be holding it too far off when you start your tie in and porosity is getting in as well as slag under the arc.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Dust yourself off gizmo, and go right back at it!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Did they look like this? I was trying to teach a kid how to weld, I told him he wasn't ready for 3-G, but he just had to try. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:The first welding test I ever took I failed. I was nervous and felt like I was under a lot of pressure to pass. After that, all the tension was off of me and the next time around I passed. I figured I already knew how to fail one, let's see if I can pass the next one.Good luck with the next one!
Reply:Lugweld, Yep it was a SMAW test and it does looks like I cooked the restart. It's a definite weak spot for me.Will-do WelderMike- I already have 4 sets of plates milled and prepared, Of course it's raining like hell here in Jersey this week! I'll just have to spend the next few days preparing plates.CEP - I've passed the bend test several times without a fail but the X-Ray is a challenge to say the least.Polarred21- Nervous is just how I felt! With employment on the line it's hard not to be. I hope your right that the next time will be easier!Gizzmo
Reply:What rods were you using in the test?Some kind of Big Blue constant current welding machineAnother smaller yet, Blue machine (it's got wire in it)
Reply:Originally Posted by Dale SalisburyWhat rods were you using in the test?
Reply:I'm not certain how old you are but every generation has its heroes. One of mine was Fred Astair. OK, it was my father's generation but also a time that I which I was a part of. Even today, there are few people who haven't seen his artistry. Curiously, during his first screen test, the director wrote, "CAN'T ACT, SLIGHTLY BALD! CAN DANCE...BUT JUST A LITTLE". Keep at it and one day, when left that test having passed it and you're off welding the next generation of whatever will continue to keep this nation great, someone will recall that someone once said something like that about you. Perserverence. It's the only thing that separates us from greatness. So, echoing what Mike, said go be Fred Astair. Go be great.
Reply:Thanks gentlemen,I'm 53 and burned my 1st rod just about three months ago. I can't expect miracles but I did have my hopes up. BTW, my favorite actor is Marion Mitchell Morrison better known as "The Duke" John Wayne. As for the grinding - I'm strictly prohibited from using one during the test , Wire wheel only. I seem to tie-in well during the root and fill,but on the cover appearance is an issue and tend to dwell a bit too long trying to shape the weld. I'm also getting small slag clusters in the restart. I'll have to play around with it some more.Gizzmo
Reply:On a structural plate test I never restart my tie in ahead of where I left off and drag back to tie in. That leaves the chance of crap being left. I always strike my arc at the back of the crater where I left off. This way your puddle is fluid and formed in with the bead where you left off as you restart the new bead. I have never failed a structural stick test.Another tool I use during this type of test is a piece of a band saw blade to pick out any left behind slag that the wire wheel can't get to.On my 3G cap I run smoking hot and carry a very large puddle.Last edited by snoeproe; 10-11-2013 at 11:01 PM.
Reply:Hotter and faster. My first structural test was actually two welds. 3G stick and 3G fcaw. I ran the stick around 110-115 all the way out. No issues with xray starting my tie ins ahead of the crater, but now that snoeproe mentions it, I may think twice next time around. FCAW was around 300ipm and 22.5. I wasn't outwardly nervous but the way the rod was shaking would tell you different. Only thing I can say is, practice more. Run that weld about 10 times before you get back to the test (if that's possible, cost wise) and by the time you get there, it'll be just another weld. Which it is. Always. Wait til you get a 6GR pipe test and can't get your big nugget crammed in the box enough to see half of what you're doing. I think I only passed visual because the two guys before me did so bad.