Mig Welding - Excessive spatter

[Jack Ryan]

@Jack Ryan I don't really understand your question. because you say that only the current is given.

it is a semi-automatic welding machine.
you may weld GMAW and FCAW.

ampere is indicated.
voltage is indicated
heat input is indicated.
etc etc etc.

can you explain what exactly you mean?

It wasn't meant to be a brain teaser.

Current is specified but you can't directly set current, only WFS. I realise the current is what is important but you would have to set a WFS, strike an arc, and read the current displayed on the machine. Obviously, a current readout with a hold facility is required plus some trial and error. It would be more straight forward to specify a WFS (along with the other settable parameters).

Things would be different if current were a settable parameter. OK, the WFS control may not be totally accurate, but neither is the current readout.

A (closed loop) synergic program is also out of the picture because adaptive control would conflict with the specified program.

That is why I asked what the machine was. I was curious if the current could be set as a parameter or if trial and error was required.

Jack

 

[denlow60]

It wasn't meant to be a brain teaser.

Current is specified but you can't directly set current, only WFS. I realise the current is what is important but you would have to set a WFS, strike an arc, and read the current displayed on the machine. Obviously, a current readout with a hold facility is required plus some trial and error. It would be more straight forward to specify a WFS (along with the other settable parameters).

Things would be different if current were a settable parameter. OK, the WFS control may not be totally accurate, but neither is the current readout.

A (closed loop) synergic program is also out of the picture because adaptive control would conflict with the specified program.

That is why I asked what the machine was. I was curious if the current could be set as a parameter or if trial and error was required.

Jack

This welding machine has a reading panel on the front. you can see what your amp is and you can see how many volts you were welding with. the protrusion length of your mouthpiece is indicated on your WPS. you can set this welding machine for different metals.

and if you want to know whether your current and volts are correct, you use an external volt/amp meter to see whether it matches the value indicated by the welding machine.

 

[Munkul]

My ISO 15614 PQRs have both wirespeed and current range which I'm fairly sure I've seen on all other ISO PQRs and WPS.

 

[denlow60]

My ISO 15614 PQRs have both wirespeed and current range which I'm fairly sure I've seen on all other ISO PQRs and WPS.

 

[denlow60]

My ISO 15614 PQRs have both wirespeed and current range which I'm fairly sure I've seen on all other ISO PQRs and WPS.

these two WPS, one from AWS and one from ISO 15609-1. have everything you need to know, but I don't think people can find it.
I the one from AWS I highlighted it in yellow.

 

[Jack Ryan]

This welding machine has a reading panel on the front. you can see what your amp is and you can see how many volts you were welding with. the protrusion length of your mouthpiece is indicated on your WPS. you can set this welding machine for different metals.

and if you want to know whether your current and volts are correct, you use an external volt/amp meter to see whether it matches the value indicated by the welding machine.

I know these things but striking an arc, holding the torch so that the stick out & arc length are correct, and then lifting the lid and checking the display for the correct current seems cumbersome. I have seen quite a few lists that give both current and WFS.

Perhaps you have a helper, but in any case, perhaps you can see why I was curious.

Jack

 

[Jack Ryan]

these two WPS, one from AWS and one from ISO 15609-1. have everything you need to know, but I don't think people can find it.
I the one from AWS I highlighted it in yellow.

As far as I can see, neither specifies WFS. The first has the WFS fields blank, the second shows current OR WFS - it appears to be current.

Anyway, I was just curious, I was not intending to make a mountain out of it.

Jack

 

[Munkul]

I know these things but striking an arc, holding the torch so that the stick out & arc length are correct, and then lifting the lid and checking the display for the correct current seems cumbersome. I have seen quite a few lists that give both current and WFS.

Perhaps you have a helper, but in any case, perhaps you can see why I was curious.

Jack

If its a witnessed weld proceedure test or a welder test then the witness notes the amps down

 

[addjunkie]

@denlow60 why does the wire get changed in that procedure between the root and the rest.

 

[denlow60]

If its a witnessed weld proceedure test or a welder test then the witness notes the amps down

these come from a PQR.
a WPS is created from the values measured in a PQR.

 

[denlow60]

I know these things but striking an arc, holding the torch so that the stick out & arc length are correct, and then lifting the lid and checking the display for the correct current seems cumbersome. I have seen quite a few lists that give both current and WFS.

Perhaps you have a helper, but in any case, perhaps you can see why I was curious.

Jack

Do you perhaps have such a WPS?

 

[denlow60]

@denlow60 why does the wire get changed in that procedure between the root and the rest.

@addjunkie
this is to be able to work effectively and to get more efficiency from your welding.
Elgacore MXX 100 / T 42 2 M C/M 1 H5
the first M is for metal cored electrode or metal powder. This allows you to create a root pass without support at the back (backing strip).
but is not as productive as the other welding wire.
with the second welding wire the Elgacore DWA 50/T 42 2 P M 1 H5, the P is for electrode core — rutile, fast-freezing stroke, if you want to make a root pass you must always use a backing strip.
this is not suitable for root pass. but this one has a better usability for filler layers and fillet welds is more cost-effective than the first thread.

the current density of wire two is higher, allowing you to weld with high steam in any position and faster.

By the way, I posted a WPS bundle of an entire project just to show how this works.

 

[addjunkie]

@addjunkie
this is to be able to work effectively and to get more efficiency from your welding.
Elgacore MXX 100 / T 42 2 M C/M 1 H5
the first M is for metal cored electrode or metal powder. This allows you to create a root pass without support at the back (backing strip).
but is not as productive as the other welding wire.
with the second welding wire the Elgacore DWA 50/T 42 2 P M 1 H5, the P is for electrode core — rutile, fast-freezing stroke, if you want to make a root pass you must always use a backing strip.
this is not suitable for root pass. but this one has a better usability for filler layers and fillet welds is more cost-effective than the first thread.

the current density of wire two is higher, allowing you to weld with high steam in any position and faster.

By the way, I posted a WPS bundle of an entire project just to show how this works.

Thank you for the detailed explanation

 

[denlow60]

As far as I can see, neither specifies WFS. The first has the WFS fields blank, the second shows current OR WFS - it appears to be current.

View attachment 442714


Anyway, I was just curious, I was not intending to make a mountain out of it.

Jack

@Jack Ryan WFS is the thread speed.
and if you want to know, you can calculate it.
your wire speed is also your ampere.

an example if you want to calculate the WFS.
your ampere is 250 and your welding machine has a WFS range of
1 + 22 m/min. then you take a watch or a stopwatch.

you set your ampere to 250 and then let the wire run together with your stopwatch for a minute then you know how much wire you use per minute.

I have told you several times that these two WPS give you all the information you need.

ampere is wire speed.

I hope this is clear to you.

 

[Jack Ryan]

you set your ampere to 250

That was the whole point of the question.

ampere is wire speed.

Really? Related, yes; the same, no.

Anyway, thanks, but my curiosity has expired.

Jack

 

[denlow60]

That was the whole point of the question.



Really? Related, yes; the same, no.

Anyway, thanks, but my curiosity has expired.

Jack

how do you calculate the heat input?
with the wire speed or with ampere.

You do this with ampere, not with wire speed.

and now I'm done with this.