Rate my weld

[rockweasel]

. . . and don't spare my feelings!

I've been trying to teach myself arc welding at home. The long term goal is to build my own power rack for my home gym. The wooden one is starting to fall apart. I'm improving, but not happy with my fillet welds. I'd like another set of eyes to tell me what I'm doing wrong. It looks like a mess to me compared with the photos in the projects section of this forum.

This is a test piece of 60x60x3mm square tubing. Current set at approx 100A. 3.2 mm 6013 rods used. I've welded/ground down and rewelded the joints a few times for practice.

Thanks in advance

 

[Brad.]

Looks like your not getting slag on there which is good, but also looks a bit flat, as in more weld on the bottom than the top like.

Not sure try upping maybe 5 amps and concentrate on the 45* angle of the filet?

 

[rockweasel]

Brad

Thanks, I'll try that.

 

[shenion]

It also looks like you are holding the rod a bit low at times (elongated ripples.)

Looks good though

 

[rockweasel]

Scott

By "low" do you mean the arc is too short or that I'm holding the rod at a low angle? I think I probably do both. I see what you mean about elongated ripples.

Thanks

 

[shenion]

Rod too low an angle.

Think of the rod as a flashlight. Hold it perpendicular it it shines a circle. Hold at an angle and it shines an ellipse. The steeper an angle, the pointier the ellipse. The ripples in one of the welds is a bit pointed.

Arc length looks ok. I tend to lightly drag 6013's as it keeps the slag from puddling up in front of the weld.

 

[rockweasel]

Well explained! I'll make that change on my next welds.

Thanks again

 

[PTvor]

It looks to me as if you have quite a big gap on that corner and the fillet between the vertical section and one of the horizontal pieces will be a feather edge rather than the usual type of fillet.

The feather edge you should be able to cope with with practice.

I don't know about the gap. I'd be inclined to make it up with dabs of weld before starting and grind it down if need be.

If you are welding something and you want it to be a good job, if possible, turn it so you are welding down into a V rather than an L and have gravity help you.

 

[rockweasel]

PTvor

The rounded edges on the square(ish) tube don't make for a tight fit where the meet. When I'm buying steel for the power rack I'll source as square a cross section as I can. I'll try holding the test piece so that I'm welding straight down and see the difference.

Thanks

 

[aametalmaster]

Try some 1/8" 7014...Bob

 

[shenion]

Try some 1/8" 7014...Bob

I'd use 2.4mm (3/32") rods.

However, 7014's seem to be a US thing. Popular here but rare on that side of the pond.

 

[rockweasel]

I've upped the current, changed the rod angle and rotated the test piece so that I'm welding flat. Only 6013's at the moment so experimenting with rods will have to wait.
I think the welds have improved. Photo attached. Feedback welcome.

Question. I used a magnet to hold the piece in place for the flat weld. When I tried a dry run with the welder off the rod would be drawn to one side or the other. As I have a hard enough time as it is keeping my hand steady I ditched the magnet and made do with propping it in position. Are magnets the best way to position and hold your work and does the magnetism have any affect on your technique?

Thanks again.

 

[PTvor]

Arc blow is caused by the current in the arc being deflected by magnetism. It's worse with DC and worse as the current increases. If you are using AC, you can counter it a bit by wrapping the earth return lead wound the work.

I've got a couple of magnetic clamps, but I don't find them that useful. They also tend to pick up metal dust and rust particles.

Make up a few vee blocks with offcuts of angle iron. Dirt cheap and very handy.

If you are welding something like that with great big gaps, you have to find a way to close the gaps before you start, say by putting down beads of weld..

Ideally the work would have no gaps or gaps of the size you want.

 

[rockweasel]

PTvor

Thanks I'll make up some V blocks.

I intend to use square tubing in my projects to keep the gaps small.

Thanks.