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Anybody have any tips on welding conduit? This stuff is light weight, easily bent, and can be used for lots of small projects, but any way to weld with flux core wire? I have tried to do it with low heat and low wire speed, but it is tricky to do without burning through, any tips?
Reply:I would guess conduit to be 18 or even 20gauge- hard to do with fluxcore. Lots of small welds is about all you can try. Also conduit is generally galvanized which makes for nasty toxic smoke and crud when welding. Grinding the galvanized off would be a good thing.
Reply:Even grinding the galvanize coating doesn't do a very good job of cleaning it for weld. I've tried both MIG and OA and neither one makes a very pretty weld. If you do try to weld the stuff, be sure to have lots of ventilation and draw the fumes away from you.JimCut an MGB and widened 11" C4 Corvette suspension and LT1 Chevrolet power & 6 spd. Pictures here:Part 1http://forum.britishv8.org/read.php?13,7581Part 2http://forum.britishv8.org/read.php?13,22422
Reply:I just welded some 1/2in conduit I had laying around to make a frame to hang stuff from when I powder coat.You are right about it being hard to weld but what I found was this.Make sure the fit up is as good as you can get it. Turn the voltage down as low as it will go and wire speed about 1 or maybe 2 and then move fast. If you do burn a hole in it then just hit it for about a second let it cool for about a second and hit it again and you can easily fill them.My welder is a 220v mig so your settings may be a bit different than mine.I am sure people with much more experience will offer better advice but this is what I ended up doing not more than 1 week ago. By the time I got it figured out my welds were looking really good, to bad it was at the end of the project.
Reply:Here is a case where fluxcore could be pushed. It will spread out the heat for less chance of burn through. That is some thin stuff. I made 5 manhole guards out of 1" conduit. I mig welded it. It was tough with an SP100 using C/25. I ground all the galv off before welding. It was easier to weld where I hammered the ends flat.Even if you grind the galv off the outside, the stuff on the inside still burns and makes white smoke. Don't breath it.Been there done that only once!David Real world weldin. When I grow up I want to be a tig weldor.
Reply:The only time I've ever used it was for a roll cage on a Honda Odyssey...back in the late 70's...and I used 1/8 6011....worked fine and never broke after many rollovers.....
Reply:I've made a lot of projects with EMT and just migged it with 035 hard wire moving fast. You should be able to do it with flux core. I grind the saddles to a good fit though. Sometimes you might have to trigger weld the not so good fitting places. Practice on scrap first.
Reply:I have heated the ends at the joint and removed some of the zinc. I try not to grind it as its a pain on the smaller diamters and usually I thin the wall. I have used E6011 5/64" diameter and ER70s-6 with about 15-16 volts and suaitable wire feed speed. I make chicken pens with 3/4" and the oldest we have now is about 7 years old and still together.Tight fitup is essential of you are using SMAW. For GMAW you can get pretty cold and stick stuff together.Have a nice dayhttp://www.weldingdata.com/
Reply:Don't know if it would work for this or not, but here goes.I make biodiesel for all of my vehicles. It is a strict no-no to use zinc coated water pipe or fittings when building a processor (zinc coated pipe is easily found here in Canada, not so easy to find black pipe). What I, and a lot of biodieselers do is use muriatic acid (cut with water of course) to get the zinc out/off. Course you'd have to either watch it, or cut it down a fair amount more with water due to conduit being much thinner than water pipe. Might or might not work *shrug* Originally Posted by gaustinI have heated the ends at the joint and removed some of the zinc. I try not to grind it as its a pain on the smaller diamters and usually I thin the wall. I have used E6011 5/64" diameter and ER70s-6 with about 15-16 volts and suaitable wire feed speed. I make chicken pens with 3/4" and the oldest we have now is about 7 years old and still together.Tight fitup is essential of you are using SMAW. For GMAW you can get pretty cold and stick stuff together.
Reply:It ain't gonna kill ya.Set up a fan to blow the smoke away- works better than trying to draw the fumes away unless you have a fan designed for exhaust.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Are you using the new Lincoln and the roll of .035 Fluxcore that came with the machine?If so try getting a roll of .030Although really you would do much better with a .023/24/25 Solid wire and gas for the thin conduit.If you switch to Solid wire the you will have to definitely remove the Galvy before weldin' as it will Pop Sizzle and drive ya mad.With the Fluxcore just weld right over it.Last edited by Broccoli1; 08-19-2008 at 06:25 PM.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by Broccoli1Are you using the new Lincoln and the roll of .035 Fluxcore that came with the machine?If so try getting a roll of .030Although really you would do much better with a .023/24/25 Solid wire and gas for the thin conduit.If you switch to Solid wire the you will have to definitely remove the Galvy before weldin' as it will Pop Sizzle and drive ya mad.With the Fluxcore just weld right over it.
Reply:If you're welding galvanized or stainless,it would be wise to invest in a welding respirator. They only cost about $15-20 for a decent one (3M 6000 series) and you buy the filters seperately at about $5-7 a pair. If it's just a one-time deal I think the disposable welding respirators run about $6-7 each.I use a 3M 7503 (last # 1=size small,2=med,3=large) mask. For example 7503 means 7500 series size large. I think the 7500 series masks are a little more comfortable than the 6000 series, but some people still prefer the 6000's.The filter is use is a 3M 2097 (NIOSH P100 rated). No more "yuck" feeling or headaches at the end of the day. Since I started wearing one if I'm working around a lot of fumes, it's made a big difference. It fits under my welding helmet no problem at all. For certain jobs I consider it a mandatory item - galvanized is one of those jobs. A fan is a big help, but without a respirator, you're still breathing some BAD stuff. Whatever you decide to do, be safe about it.Click here for guide to NIOSH filter ratings Attached Images-Matt------------------------------------------
Reply:Originally Posted by Broccoli1It ain't gonna kill ya.
Reply:Originally Posted by HephaestusIt killed this guy ->http://www.anvilfire.com/iForge/tutor/safety3/index.htm
Reply:Originally Posted by Broccoli1No it did not.
Reply:Here are the main points when dealing withgalvanized metal: Metal Fume Fever is the result ofoverexposure to zinc fumes from welding,cutting, or brazing on galvanized steel. Metal Fume Fever is a shortterm illness********with classic flulike symptoms. The permissible exposure limit (PEL)according to OSHA is 5 milligrams of zincoxide fume per cubic meter of airalwaysmonitor and measure your breathing air. To avoid the illness, keep your head out ofthe fumes and do not breathe the fumes.Use enough proper ventilation and/orexhaust. If uncertain about the ventilation,use an approved respirator. There are no known longterm effects ofthis disease.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:I have mig welded conduit before with .035 hard wire,however my grandfather always brazed it with great sucess in the past.
Reply:Originally Posted by HephaestusCare to enlighten us?
Reply:Originally Posted by David RIt makes you shake, gives you the sh*ts, a headache and one lousy feeling body.Like I said, only once for me!David |
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发表于 2021-9-1 00:50:18