Stick Welding Help Please!

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Hey all,I'm in need of some help from you pro's. I'm a Communications / Electronics tech, now my boss has given me the job of welding up quite a number of Solar panel frames. I've just completed my first frame and mounting, using a stick welder I mainly welded 40x40x5 angle iron in a configuration to suit the solar panels. My problem is, I know nothing, nothing (Hogans Heros ) about stick welding. I can MIG weld with ease but this seem's to be a different ball game.When I'm welding I seem to get alot of splatter...infact I have burns on my arms and holes in my shirt....and before you ask, no I'm not to close to the weld . Is this normal, also the welds are never nice looking...the welds seem to be penertrating the iron fine...infact too well sometimes. Also the welds have a lot of that burn off stuff you wack off afterwards. The welds are normally not complete..they have little pits in them and look very ugly in general.Also when I'm welding I dont seem to have much time to get a pool going because it either bogs up with weld or it burns through the iron. The welder is a good one so I've been told, our ex-worker used it with great results so I know its me. The welder has a digi meter on the front reading from 00 to around 200 I think...and I'm not sure what rods I'm using but again, they have been used by another person with good results.What am I doing wrong? Please helpppppppp....any pictures of what a good stick weld sould look like would be helpfull also. Cheers.
Reply:This link is to a thread about a welding contest a manufacturer had here about a month ago.Look at the links in post number 12 by Tensaiteki. All the welds were done with 6011 rod.http://weldingweb.com/vbb/showthread.php?t=22160Welds done with different rods have different characteristics. These are a a good example of some 6011 welds. It would be a big help if we knew what type and size rod you were using and the amperage setting.Yup
Reply:Originally Posted by JarmizzI'm a Communications / Electronics tech, now my boss has given me the job of welding up quite a number of Solar panel frames. I've just completed my first frame and mounting, using a stick welder I mainly welded 40x40x5 angle iron in a configuration to suit the solar panels.
Reply:I'm with 69 chevy Did you tell the boss you've only used a mig?     If you did and he wants you to do the welding still then tell him to stop being such a tight aRse and go buy you a cheap mig.   Otherwise tell him to go hire a welder for the job. (and I mean the man not the machine)I'd rather be hunting........USE ENOUGH HEAT.......Drifting around Aussie welding more pipe up, for something different.....wanting to get home.
Reply:I applaud your efforts to educate yourself.As far as i am concerned your boss should be put in jail.There is a law that says the employeer is responsible for the training and safety of the worker. IT is a FELONY not to.ALSO   - if it is a foreman, that person CAN be held liable.Now about your problems. We would like to know the thickness of the metal you are using. Probably 1/8 electrode. 125 amps. DCSome electrodes like 6010 or 6011 will penetrate but will really be hard on clothes. The 6011 would be good on the inside of the frame because the weld is really flat without much build up and has deep penetration. This would save time by not having to grind welds that are too high. MIG welding would could give a lot of build up if the welder is not skilled. NEVER wear polyester clothes while welding. Do you have a protective leather jacket or apron? Gloves?6013 electrode would be better as it is a general purpose electrode with medium penetration and medium build up.All the corners should be tacked up before final welding.Bevel the weld joint before welding with a 4 inch  hand grinder, It also makes it easier to see the weld joint.That brings up another thing, your welding helmet and # of glass you are looking thru.All eyes are different but stick welding (SMAW) in general you would want a #12-!4 welding glass.Also if you make a funky weld on the inside corner (on the inside) it is going to be diffacult to grind, and whatever goes inside the frame may not lay flat or it could get cracks from stress of not laying flat in the frame..It needs to be welded on both sides if the weld does not fully penetrate.Oh One more thing .... It is against the law to weld within 50ft of another worker without a welding curtain to protect them from the welding light. The curtain must be about one foot off of the floor so YOU do not die from smoke or lack of oxygen.I have actually seen shops where welders had no curtains between themselves and people doing other work in the shop.Hope you do not hurt yourselfLast edited by Donald Branscom; 08-12-2008 at 10:26 AM.AWS certified welding inspectorAWS certified welder
Reply:Originally Posted by 69 chevyWhat kind of boss sends an untrained electronics tech to do this kind of welding job?  Will you be doing the payroll next?And the powers that be at this forum wonder why I get such a giggle out of reading the daily posts such as this one.  Un-freaking-believable.  Ripley's Believe it or Not has nothing on this forum!
Reply:Well I never thought in a 100 years it would turn into a employment matter....any way I look at it as a adventure, improving my skills in all areas  And my boss also looks at it like hes upskilling his workers...trainning is not needed as with a little pratice and help from places like this, one can learn to do any time...mind over matter people.Now, as for the rods...they only info on them is as follows.Ph68 E6013 E4112. Steel I'm welding is normally 4mm thick angle iron.I will try and get some photos...also I might try winding down the power so that I have alittle more time to gather my self before moving along the metal..the lengh of the weld needed is normally only around a inch to 2 inches long..
Reply:Training is not needed huh.Lower the heat to give yourself more time? Oh brother!Yeah i guess i spent all those years in welding school for nothing!You gave the thickness of the metal in Millimeters too.AWS certified welding inspectorAWS certified welder
Reply:Originally Posted by JarmizzWell I never thought in a 100 years it would turn into a employment matter....any way I look at it as a adventure, improving my skills in all areas  And my boss also looks at it like hes upskilling his workers...trainning is not needed as with a little pratice and help from places like this, one can learn to do any time...mind over matter people.Now, as for the rods...they only info on them is as follows.Ph68 E6013 E4112. Steel I'm welding is normally 4mm thick angle iron.I will try and get some photos...also I might try winding down the power so that I have alittle more time to gather my self before moving along the metal..the lengh of the weld needed is normally only around a inch to 2 inches long..
Reply:Originally Posted by Donald BranscomYou gave the thickness of the metal in Millimeters too.
Reply:Originally Posted by wirehuntWhich is good to see, you'll catch up with the rest of the world soon  If you need the inside welded I'd just prep the outside so it can all be welded from the outside so hopefully you don't need to try and clean up in that tight corner.   A 3.2mm rod would do the job on your 4mm angle iron with two runs.
Reply:mm is used in New Zealand...us young ones were never brought up using inches.I wasnt meaning that you don't need to go to Welding School, all I was pointing is I have a different way of thinking. If I need sometime made/done I teach my self or study info on the net and try to compete the job my self. If I fail then Ive still learnt something and know what not to do in the future. I hope I didn't offend you with my comments, I would love to go to welding school...hell I've even looked into it. The local polytech/schools don't do night clases for welding and the nearest place that does is a 3 hour drive so I don't have the choice.Now as for my employer, the gear I am making will sit up on a hill for tens of years...no one will see it again for as many years...theres no one to hurt up there and I've insured that the frame is beyond strong so that it doesnt decide to fall off the hut and damage anything. However I will pass on your guys thoughts and see what he has to say..also maybe the rules over here are different to yours. Any who, Ive completed my first large frame and turned down the heat (thanks Donald) and slowed down my welding and it I've had great results (see, ive learnt something Donald, amazing that!) I will continue to play and let you guys know how I get on.James.