Completely forgotten how to....

[UserError]

Hello.
In the olden days when I was a youngster, I could weld a bit, not pretty but held things together.

Have dug my old welder out for a practice & can't for the life of me get a bead. I've read guides, watched YouTube and spent a number of hours practising.

I've got some bits of new/clean 3mm steel, ground shiny and brand new 2.5 Bohler 6013s.

Most of the time it's like the slag & filler are being blasted away. I weld along, but after there is practically nothing there, just the odd blob of weld & slag. This isn't mentioned in the guide to faults on this site! I'm using the amp range 65-85 ish. If I drop the current to 60/65, the rod sticks. I've tried more/less current, faster/slower, various angles, arc length. Rods are dry, been in airing cupboard.

I can't get any penetration either.

I would have thought I would have improved a bit in the 6 hours or so that I've spent, but it's as bad as the start.

Can the machine go bad? - I know they're pretty basic & reliable as there's not much to them.
Could the steel be 'wrong'. It is about 25mm x 3mm in ca 5m lengths galvanised - it's something specific as there's loads of it in tubes in a dinghy compound.

I'm at a loss and any tips would be appreciated.

 

[Windy Miller]

You DID grind of the galv didn't you?

 

[Wendelspanswick]

Are you grinding through the zinc to the base metal or just grinding the zinc 'shiny'.
Arc is a slow process, from what I have seen most beginners move the rod way to fast and have to long an arc length, try making a puddle of weld with the rod almost touching the metal.

 

[Endeleus]

Try a different rod. Some rods and machines just don't mix - I can barely stick two pieces of metal together with some 6013's on my machine, but other brands / rods are fine.

I thought I was just never going to be any good at stick welding until the day I bought a different brand of rod.

 

[UserError]

You DID grind of the galv didn't you?

I would have thought so, I gave it some good passes with the grinder - and the cut ends would definitely be free.

 

[UserError]

Try a different rod. Some rods and machines just don't mix - I can barely stick two pieces of metal together with some 6013's on my machine, but other brands / rods are fine.

I thought I was just never going to be any good at stick welding until the day I bought a different brand of rod.

I've just invested in a box of Bohlers... But also in my welding box are some old 6013 SIP 2.0 & some unidentified 2.5s ( sad remains of a bright blue box & blueish coating on the rods?) I get equally carp results with all of them.

 

[UserError]

Are you grinding through the zinc to the base metal or just grinding the zinc 'shiny'.
Arc is a slow process, from what I have seen most beginners move the rod way to fast and have to long an arc length, try making a puddle of weld with the rod almost touching the metal.

Re galv - must be gone, not least as I ran out of scrap metal & had to grind my junk welds off & can't see the galv surviving that. Next session I will double check & try & go really slowly.

 

[Kent]

Forget welding galv. It can be done after lots of prep but it's hazardous and nasty to weld

Sounds like your whizzing along with a great long arc - but we can only guess

Drag the rod slowly backwards at 45 degrees - once and only once you see the puddle forming. Arc length should seem as if it's in the puddle but isnt

 

[dobbslc]

Polarity?
Try a different type of steel, it could be you've got some weird stuff there.

 

[Kent]

It's not polarity. 6013 swing either way electrode negative for reduced penetration on thin positive for regular use

 

[cocker]

Forget welding galv. It can be done after lots of prep but it's hazardous and nasty to weld

Sounds like your whizzing along with a great long arc - but we can only guess

Drag the rod slowly backwards at 45 degrees - once and only once you see the puddle forming. Arc length should seem as if it's in the puddle but isnt

That's sound

I would be starting at 100 amps first then having a tweek

 

[Kent]

These are 2.5 mm yes? 100 amps is very heavy on the juice
70- 100 being the range of a 6013 2.5 mm
100 is something I should do welding routes or thick bar on railings. On 3 mm you might find you just blow holes

 

[UserError]

I haven't got access to loads of metal. I will try & get some other stuff if I can.

I need to weld at least partly onto galv, as I need to put some temporary bracing straps onto a damaged boat trailer frame to get it to the repairer (stacking dinghy trailer, bent by a height barrier. I straightened it using a jack & chain, but could only do this after cutting up from the bottom about 50% of the tubing height. Trip is only about 2 miles but includes a section of main A road & a lot of very aggressive speed humps at the club end)

The trailer frame is in good condition and galvanised & I will have to grind that back. If I can get down to the repair place I'll see if I can scrounge anything.

 

[UserError]

Forget welding galv. It can be done after lots of prep but it's hazardous and nasty to weld

Sounds like your whizzing along with a great long arc - but we can only guess

Drag the rod slowly backwards at 45 degrees - once and only once you see the puddle forming. Arc length should seem as if it's in the puddle but isnt

I have tied slowly, then slower, Maybe the galvanising is thicker than I though, if this is stuff for use in a coastal environment. I guess it's just try & try again.

 

[UserError]

Polarity?
Try a different type of steel, it could be you've got some weird stuff there.

Basic buzzbox - no polarity options. I did check the cable attachments & they go to the right icons.

I'm beginning to wonder about the steel & will try & find something else - hard to find 3mm steel anything lying around in a domestic environment :-(

 

[Kent]

I have tied slowly, then slower, Maybe the galvanising is thicker than I though, if this is stuff for use in a coastal environment. I guess it's just try & try again.

Hot dip is hot dip varies but genrally it takes a fair amount of grinding to.remove ( also wear ppe for this)