Stick question

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Can someone kick me in the right direction to figure out what settings I need to set me welder on? Looking for a general chart that says what the settings should be for welding different metal. Example 2"x2" square tubing to 3/8" plate what rod. Say for making a welding tableI am slow so bear with me.Thank you very muchRedneckI have not welded in about 18 years, So I need lots of helpHobart Stickmate AC/DC (Present from my wife)
Reply:rule of thumb is you have to set your machine to the smallest part being welded.  If you try to set your machine for welding 3/8" plate, you will blow through that 2x2 box tubing.  There are ways to cheat around that, but i wont get into it.I would use 7018 1/8" on DCEP (DCRP) and just run some test beads on scrap and adjust the amperage till you get a puddle you can control. Start off between 110-125 amps and adjust from there.In my opinion this is the best way to set a machine, dont go by the numbers, go buy the puddle.  this is because every machine runs different, i have 2 millermatic 250's and i run them on different parameters to acheive the same puddle.hope that helps
Reply:I would set the machine high enough to achieve a puddle in the thickest metal. Keep the puddle on the 3/8" and wash it onto the tubing.  Good fit up is important.About everything I do involves 1/16" wall steel.  I can only imagine/remember the frustration of trying to weld 1/16 tubing to 1/4" or thicker plate with only amps enough for 1/16".  Actually, been there, done that.  Puddle the larger material, control the puddle.Last edited by tapwelder; 03-27-2008 at 08:51 AM.
Reply:That is right about every machine being a little different. I haven't seen it addressed on here anywhere but the length of your leads has quite a bit to do with your amperage setting, especially with DC machines because of voltage drop. I used to carry 200' of lead, 90' ground,110' stinger to reach some of the places I had to go. It requires quite a bit more amperage than say 20' leads.Another rule of thumb is: thin metal, small rod, thick metal, big rod. As you gain experience this will all fall in line.
Reply:When welding thin to thick always concentrate heat into the thick and let it flow into the thin. If it is .120 wall or heavier tube I just weld it like any other fillet. I normally run 1/8 7018 at about 140 amps or so. You should probably start at about 120 and adjust from there.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Oh boy!  Another "help me set my machine but you have to guess what my machine is first" question...We did have a clue with the word "rod" though.  Assuming it's a basic Stick welder with just one big dial, there isn't much to say.  Your ability to pick the right number will get better within the first minute, quicker than it takes to reply to this thread.Rod selection isn't very critical either for most hobbiest's projects.  You'll find you like running 6013 or 7018 the easiest, but shouldn't really buy 7018 unless you are going to use it right away.  6011 is for greater penetration, but more difficult to use.Is your machine AC/DC or just AC?  That makes a big difference.Last edited by MAC702; 03-29-2008 at 12:29 AM.
Reply:also, what wall thickness is the 2x2 tube?
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