Plug welds - some guidance needed

[Fuchs915]

Hello all,

Making progress with the 130 Pocket Turbo, albeit a bit slow. Have been trying different welds out but plug welds are proving a bit of a challenge. I have the welder set to 1 max, wire speed 5-6 (12 o'clock to 1 o'clock) using 0.6 wire on 1.2mm steel with 6mm drilled holes. Using Argon/CO2. Stick out about 1 cm and gun just off vertical so I can try to see what is going on. (Welding tip sits about 5mm below edge of shroud, is that correct?) The technique I am using is to start in the middle for a count of 2 and then move out to the edge for another count of 2. I am trying to plug vertically as I'll be working vertically when doing the car at this stage. I seem to end up with gaps around the edge or burning the edge away of the top sheet. I have tried using 1 min which didn't seem to make a huge amount of difference, but it could just be my inexperience. Am I spending too long on the weld? Speed wrong? Holes too small? Appreciate any thoughts on what I should change to improve matters.

Thanks

Kevin

 

[Coo]

certainly move torch in a spiral from centre of the solid bit, round and out to the edge of your metal with the hole...

Look and see what its doing rather than count seconds...you'll see pool forming, then get moving...

 

[pedrobedro]

Make your holes bigger 8mm at least and make sure your front metal is tight up to what you are welding it to.

 

[dan.taylor.1]

Yeah 6mm is way too small for a plug weld. Needs to be 10mm I'd say (looking at most on YouTube and from experience working on cars).

 

[Rocketman]

I have had problems especially when the back steel is thicker with a 6mm hole in the front material. Making it 8mm+ is a lot easier.

 

[doubleboost]

This is how I do them
Starts at 4 .00

 

[Sean]

if the top plate is burning back have you clamped the 2 pieces tight, and cleaned the face of the lower piece back to clean shiney? any contamination including weld thru primer can blow the weld out. there is also another technique where you use a smaller hole turn the wire speed down to minimal and the power up and just buzz the spot, works well with my thin metal.

 

[Kent]

As said forget all the counting go off what you see. BTW not being derogatory but if you cant see exactly what is happening fix that with glasses on a new lens / shade in the visor.

 

[Fuchs915]

Here are some snaps. Using 7 mm holes now, which seems easier. Been playing around with settings. 1 Max or 2 Min (1-5 in the pics) seemed to destroy the top plate. I guess it is me being slow...? 6-12 are on 1 Min setting - 12 I had a couple of goes at . How do they look? The fronts aren't pretty, but look OK when ground back. The other heat marks are from some practice seam/overlap welding

Cheers

Kevin

 

[Monkey Harris]

I like no10....

They look effective from here..

 

[Fuchs915]

I like no10....

They look effective from here..

Thanks for the feedback. I seem to regularly not fill the hole in the front, usually leaving a gap at the bottom. I suppose I just need to remember this and make a conscious effort to go to the bottom of the hole (no jokes please!). I have some more pictures of another set of welds that I can post later, mostly similar to these.

Cheers

Kevin

PS, you won't like no 10 on the next batch

 

[Monkey Harris]

 

[Kent]

The best test is destruction testing on these. I cant see much at all about a welds strength for a photo as I have seen many a fine looking migweld give up. Get a cold chisel and hammer or a vice and some big grips etc. or and get between them, break it and see were and why it gave up and if it might be possible to improve at all. Its just a bit of sheet not like you want to hang it on the wall so just go for it