Upper limits of Syncrowave 180SD

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the local steel supply is having a sale on 1.25x1.25x.25 ($20/20 foot) inch and 2x2x3/16 ($24.60/20foot) inch angle iron and i'm planning a few projects.my question is, is my syncrowave 180 able to weld up to 1/4 inch thick material?  would i need to bevel the joints?also, which one of these two angle irons is stronger?  I might build a cart for my synchrowave, which weights a ton.tia
Reply:Yes,  you should be able to weld either of these without any problems.  Minimal beveling is req'd.  I'd leave a 3/32" gap to ensure you get full penetration.  Might be a little thick in the corner where the angle sides meet.2x2x3/16" is stronger and stiffer.  But heavier as well.  Keep this in mind.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Thanks for that, Dab.why is 2x2x3/16 stronger and stiffer then 1.25x1.25x1/4?  I assumed that thick would be stronger.  I guess its the 2 inch sides that made it stronger then the 1.25 sides?thanks
Reply:Oxy:I have an aircooled #17 torch and it gets pretty warm when I turn up the amps. It will do what I want, I just can't be in a hurry. Another possibility: since you've learned O/A and TIG, recently, get a stick electrode holder for your Sync and learn some stick welding. 7014 isn't humidity sensitive, so will last longer between projects and doesn't need to be baked in an oven.9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Originally Posted by oxy moronthe local steel supply is having a sale on 1.25x1.25x.25 ($20/20 foot) inch and 2x2x3/16 ($24.60/20foot) inch angle iron and i'm planning a few projects.my question is, is my syncrowave 180 able to weld up to 1/4 inch thick material?  would i need to bevel the joints?also, which one of these two angle irons is stronger?  I might build a cart for my synchrowave, which weights a ton.tia
Reply:i have the stick electrode holder for my sync 180.  even though i know little about tig and oxy, i know even less about stick welding.  I do wonder, though, with the same welder, will using the stick welding process allow me to weld thicker material?
Reply:Originally Posted by oxy moroni have the stick electrode holder for my sync 180.  even though i know little about tig and oxy, i know even less about stick welding.  I do wonder, though, with the same welder, will using the stick welding process allow me to weld thicker material?
Reply:Basicly you're right.  Stiffness is a function of cross sectional area.  Round tubes are stiffer than solid bars, but not as strong in tension if the same OD.  Rectangular tubing is stiffer in one direction(the long side) than the other.  Shape matters, and some folks forget this occasionally.  (not you, just speaking in general).2x2 angle is stiffer than 1.25x1.25 angle, if the thickness is the same.  Width of the web counts for more than thickness in this situation.  In this case the cross-sectional area for 2x2 angle is greater than 1.25x1.25 angle, so the 2x2 angle is stronger  in tension as well.  What are the stiffness 'break points' between aspect ratio and thickness?  I can't tell you those off the top of my head.  The references are out there in mechanical engineering and structural engineering textbooks if you need them bad enough. Originally Posted by oxy moronThanks for that, Dab.why is 2x2x3/16 stronger and stiffer then 1.25x1.25x1/4?  I assumed that thick would be stronger.  I guess its the 2 inch sides that made it stronger then the 1.25 sides?thanks
Reply:Originally Posted by milwironI've 6013 stick welded a lot of 1/4 and 3/16 angle iron with my old 180.I used 3/32 and 1/8 rod in the 60-70 amp range.At the time I was running the welder off a portable generator, I was more limited by the  generator capacity than the 180SD.
Reply:With up to 180 amps DC+/- you can run pretty much any 1/8" rod and get at least to about the middle of the amp range on many 5/16 rods.6010/11 at 1/8" runs at max at about 130amps, 6010/11 in 5/32" maxes at 175amps. These will eat into heavy steel like you would not believe.7014 at 1/8" maxed runs at 140 amps 7018 1/8" maxed runs at about 170 amps.Grab a small box of these and play a bit. V'd out and multi pass there's not much you can't weld in thickness with that machine.
Reply:Originally Posted by oxy moronWTF? no way!!!! im amazed.I tried to tig two pieces of 1/4, 3 passes, not too much penetration at all.  Thats with the dial all the way up to full (150 or 180, whatever the max is.  you're saying you can stick weld 1/4 inch thick stock with 60-70amp?  Amp as in the dial on the sync welder right?for comparison, i have my machine set at 60-70amp when i'm butt welding (tig) 1/16 walled square tubing