Filling the Fillet

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Ok, can anyone tell me the "secret" to filling the fillet welds with enough filler?  I can make nice looking fillet welds, they are just light on the filler each time.  Should I ne running a striaght bead, weaving, etc??I have tried this so many times and I just cannot figure it out.  The only way I was able to get a good fill on some 1/8" MS was when I laid some 3/32" filler in the joint and just ran over it.  Other than that I tried stuffing additional filler and it just does not work.  If I keep stuffing the filler the puddle cools too much and I have a cold bead.I am mainly working with 1/8" and 1/4" MS with 3/32 Tung and 1/16" filler for the 1/8" and 1/8" Tung with 3/32" filler for the 1/4".Thanks!Build a Barstool Racer at BarFlyRacers.com!
Reply:Perhaps you could use bigger filler and a bigger (a little) puddle.   Got pics?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Hi David,I got some pics I will post later tonight after some more test runs.I will try feed some 3/32" filler into a 1/8" fillet tonight to see what happens.  I just know there has to be some method to the madness because I can run some beautiful welds when I am not doing fillets.Build a Barstool Racer at BarFlyRacers.com!
Reply:Fillets take more heat than groove or flat.  Maybe that will help.Maybe you need more than one pass.  1/4" could take up to 4 passes.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:That's a new thought - use the tig on mild steel, lol. Can't help any as I always use the mig or sticks on stuff that size. David's suggestion on the multiple passes is probably your best bet. Even with mig and stick on larger fillets you use multiple passes. I have used the tig on AL fillets of that size and did use multiple passes.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:I was having the same problem on 1/8" fillets also, so a multi-pass would not be the answer on the 1/8".What I did do was instead of moving 1/8", dip, move, dip I moved about 1/16" and much slower and dipped twice a second and it filled the joint.  I also did the same on the 1/4" MS with an 1/8" Tung and 3/32" filler and it filled the joint in one pass.I then clamped the part to the table and bent the metal over to a 90 deg pulling away from the welded side and it held.I will post some photos tomorrow.Build a Barstool Racer at BarFlyRacers.com!
Reply:I may have some time today, my job canceled.  I will try 1/4" in one pass.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Ok, I ran a few more single pass fillets welds on 1/4" MS tonight.  If I look down the side of the weld it is pretty much flat (filled).  I am not sure how much better the bead appearance can get with steel.I was using 1/8" Tung.  3/32" Filler with Gas Lens.The photos make the welds look worse they they appear for some reason.  I also attached a photo of a corner weld I did on two pieces of 1 x 1 x 1/8 angle I did with 3/32 tung, 1/16 filler and 125A. Attached ImagesBuild a Barstool Racer at BarFlyRacers.com!
Reply:They look really good to me.  Are you using 70S-2 or 70-S6?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I am using 70S-2.  That's all I have been using for a while now.Did you get a chance to run some test welds the other day?Build a Barstool Racer at BarFlyRacers.com!
Reply:Originally Posted by malichI am using 70S-2.  That's all I have been using for a while now.Did you get a chance to run some test welds the other day?
Reply:I found some time yesterday to play around.  I did 4 fillets.  One was a bead, one was with the torch in a circular motion to make a bigger bead, then a multipass, then Zaps stitch weld. (where is he?)On 1/4" plate you only need a 3/16" fillet.  If you put this fillet on both sides, Its a sound weld.  Like I said earlier, I think you got it already.I dip or stick at the front of the puddle and let the heat suck the filler in.  You can see how often I dipped by how close the waves (I don't want to say dimes) are.Bead profile and 3/16" fillet gauge.Last edited by David R; 02-23-2008 at 07:24 AM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I used 185 amps most of the time.  Travel speed was regulated by the puddle.  1/16" or 3/32 70S-2 filler.  I used 1/8" tungsten, but 3/32 would be fine.  Circular motion with the torch.  MultipassStitch weld  Zap is much better than I am.In all cases the first pass was enough for 1/4" plate.DavidLast edited by David R; 02-23-2008 at 07:21 AM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:nice beads there david.  nice pics as well.  i have to work on my pics, and my welds...
Reply:Hi David,Can you give us your setup?  Tung, Filler, Amps, and approximatly how many dips of the filler before each move and how far apart was each move?And were you using a gas lens?  The beads look pretty nice.Thanks!Build a Barstool Racer at BarFlyRacers.com!
Reply:Originally Posted by David RI used 185 amps most of the time.  Travel speed was regulated by the puddle.  1/16" or 3/32 70S-2 filler.  I used 1/8" tungsten, but 3/32 would be fine.  David
Reply:Opps...  Sorry, I was distracted by the photos...  Thanks!Build a Barstool Racer at BarFlyRacers.com!