critique my welds?

admin

well here are my first welds, i know they suck....and seem erratic because i stopped and started quite a few times checking to see how my weld looked, i even through in a tack weld in the middle of it, im using a millermatic 251 and thats 1/4" steel im welding on, is it normal to have the black spot where i start my welds at? also is it normal for it to spit and sputter the first second or so of the weld? and its nighttime in a dark garage so i couldnt see the metal too well and kinda swerved around the line  thanks,spencerim a newbie
Reply:i think i should probably crank up the voltage a little bit, it looks like the welds are narrow and tall...i was running 19 volts and 320% wire feed speed with .035 wireim a newbie
Reply:Hi, just my .02 here but try some thinner material. Every machine is different, even two identical millers, but 19 volts seems a little low. If those were 2 pieces, then bevel the edges and you will get better penetration to start. Your wire will naturaly want to 'push' when you start. Thats the spit and spatter, higher voltage will help this. It sounds like a no brainer, but concentrate on your eye contact with the puddle. I had the tendency to look at the flash and not the puddle. Once I made it a point to see what I was doing, then it naturally improved.If all you have is the 1/4 inch to work with, turn up the heat and go to town, try different joints. Outside and inside corners, butt, lap etc. Have fun.Bill
Reply:Just try to keep a steady hand, and let the welder feed the rod into the puddle as you move along. You may want to up the amps a bit. Your weld looks like you are definitely wandering, so that is an easy fix. With a steady hand, the penetration will get a lot better. It's all practice!!
Reply:Just paly with the controls.  Hold the torch in one place and adjust each control, alternately.  As mentioned turn up the heat and play with the speed.  Listen for the frying bacon sound.  Wandering is not that big a deal if there is no line to follow. Welding in the dark is like writing in the dark.  Check the shade on your helmet might need to be lighter.An auto darkening helmet would help vision a lot especially with starts and stops-- Assuming you do not have a a/d helmet.
Reply:Originally Posted by tapwelderJust paly with the controls.  Hold the torch in one place and adjust each control, alternately.  As mentioned turn up the heat and play with the speed.  Listen for the frying bacon sound.  Wandering is not that big a deal if there is no line to follow. Welding in the dark is like writing in the dark.  Check the shade on your helmet might need to be lighter.An auto darkening helmet would help vision a lot especially with starts and stops-- Assuming you do not have a a/d helmet.
Reply:I guess I'll toss in a thought or three...You're welding metal that's pretty rusty for a mig...stick will do that without a problem, fluxcore...maybe, but mig will sputter and spit.  You probably should hit the surface with a grinder before you even try running a bead with gas and make sure you have a good connection with the clamp.  Judging from the marks on the metal, you were getting a lot of sparks and spatter.  You probably need a bit more heat still and maybe a little less wire speed.  Slow down on the travel speed to let the workpiece get hot.  In flats, you can really crank up the heat.  Use both hands and steady yourself...lean against something if you can...If you have good thick gloves, you can use one hand to hold the end of the gun to get better aim and control.  In short, it looks like you are wandering a bit and maybe moving a bit too fast.  Not a big deal right now, but something to work on.  You can use angle iron as a guide for the gun...it might help keep you steady and help pace yourself.  The second set looks a lot better than the first.  Progress comes from practice.  keep posting those pix...before long, you'll be making textbook welds.  Good job.Smithboy...if it ain't broke, you ain't tryin'.
Reply:I agree with smithboy...hit the metal with a grinder or wire wheel or even a brush, that's some rusty and dirty metal. Always remember, a good weld is always prepared.
Reply:Yeh, I'll just ditto smithboy and microzone. Clean up the metal. Crank it up a bit.
Reply:My thoughts exactly. The welds still look a little cold and clean material will definately help. You can't be too clean when welding. Preparation is 75%, if not more, the fit, then, of course, the weld itself. Practice, practice, practice. Remember, perfect practice makes perfect.
Reply:I agree, you've done something to improve the second set of welds.  In the second to the last photo, there is a couple of inches on the right end that are starting to look like you're getting enough heat.  Really try holding the gun at a constant distance from the workpiece, this can have a large effect on the weld current with a constant voltage power supply.
Reply:burn it in!---- practice -- just practice -  it looks good slow down an  watch the puddle
Reply:If you want my .02 I would think that a good setting is 24.5 volts and 250 FPS.Try keeping the hand steadier. Anyway continue practicing
Reply:Practice Practice Practice! Aside from that, the biggest help for me when I was first starting was learning to hold the gun with both hands whenever possible. For someone that isn't a surgeon, its night and day. Get comfortable, I do a lot of welding on the floor and its anything but comfortable. Also, take your time, slow your wire speed, bump up the heat, and relax.Before you know it that gun will feel like an extension of your body.
Reply:thanks alot guysim a newbie
Reply:that talk about cleanliness ? yes; in spades  ! when someone has an ALUMINUM casting  like a motor cycle engine part , I try to impress them that cleanliness is next to Godliness , i tellem : first get it clean, then SANITARY , & finally , get it STERILE ! Hard to impress them how important it is (the prep ) I'm not so much a fanatic , on steel . even so, it's all so important .
Reply:i grinded the steel down and cranked up the voltage to 25 and cut the wfs down to about 260 and i got some sweet welds....they look better than the ones on my buddys $600 bumper on his truck  , and they got good penetration too....im a newbie