1/16" Seismic Flux Core Welding | Vertical 3F

Weld.com
20 Dec 201909:15

TLDRIn this welding tutorial, the host demonstrates the use of 1/16-inch diameter flux core wire for seismic applications, particularly on materials like 3/4-inch plate in a vertical 3F position. They discuss wire specifications, polarity, and the importance of correct setup with a focus on safety and technique. The video provides tips on weld width, travel angle, and maintaining a steady hand for quality results, showcasing the process from setup to inspection.

Takeaways

  • 😀 The video demonstrates welding with 1/16 inch diameter flux core wire, which is self-shielded and suitable for seismic applications.
  • 🔍 There's a 'T' designator at the end of flux core wire types, with T3, T4, and T6 being DC positive, indicating the correct polarity for use.
  • 🧰 The wire used in the video, Select 78, is suitable for materials like 3/4 inch plate and is recommended for vertical welding in the 3F position with a filler weld.
  • 📏 A good rule of thumb for welding is that the width of the weld should be about five to six times the diameter of the electrode.
  • 🔧 The video provides a comparison between the commonly used 0.045 diameter wire and the 1/16 diameter wire being used for the demonstration.
  • ⚙️ The wire feeder setup includes 1/16 knurled drive rolls, and the welding parameters recommended are 170 inches per minute at 18-19 volts, though the presenter found 185 inches per minute and 19 volts to work well.
  • 💨 The video emphasizes the importance of fume extraction when welding indoors to avoid inhaling harmful fumes.
  • 👷‍♂️ Welding technique tips include maintaining a 45-degree work angle, staying in the center of the puddle, and using a slight side-to-side oscillation for even coverage.
  • 🛠️ Post-weld inspection is crucial to check for proper fusion and absence of porosity, with the video showing how to remove slag and inspect the weld.
  • 🔄 The presenter discusses the appearance of the weld with T6 and T8 wires, noting a glossy appearance without typical ripples, which is strong and suitable for seismic applications.
  • 👋 The video concludes with a reminder to terminate the weld properly to avoid issues with arc starting on the next pass.

Q & A

  • What type of welding wire is being used in this video?

    -The video uses a 1/16 diameter flux core wire.

  • Is all flux core self-shielded wire run on DC negative?

    -No, not all flux core self-shielded wire is run on DC negative. The wire's polarity depends on the designator at the end of the flux core wire.

  • What are some applications of Select 78 wire?

    -Select 78 wire is good for shipbuilding, offshore rigs, and other seismic applications such as cyclically loaded structures like bridges and buildings.

  • What is the recommended welding speed and voltage for the 1/16 diameter flux core wire?

    -The recommended welding speed is about 170 inches per minute, and the voltage should be between 18 to 19 volts. However, in the video, the welder found 185 inches per minute and 19 volts to work well.

  • Why does the welder not use a nozzle while welding?

    -The welder does not use a nozzle to allow viewers to see the exact stick-out length, which helps preheat the flux inside the wire.

  • What safety precautions are recommended when using this type of welding wire indoors?

    -Good fume extraction is recommended, and welders should avoid standing over the fume plume to prevent inhaling harmful fumes.

  • What is the suggested stick-out length for this welding process?

    -The recommended stick-out length is 3/4 to one inch.

  • What work angle is used for the weld in this video?

    -A work angle of roughly 45 degrees is used, which is dead center between the two plates being welded.

  • Why is it important to maintain a specific contact tip to work distance?

    -Maintaining the correct contact tip to work distance ensures proper preheating of the flux and helps maintain the weld quality.

  • What does the welder do to improve weld consistency?

    -The welder slows down and holds the sides a bit longer to improve weld consistency.

  • How does the welder address the issue of a ball on the end of the wire?

    -The welder clips the wire after each weld to ensure a clean arc start and sets the distance at 3/4 to 1 inch before starting the next weld.

  • What are the characteristics of the weld appearance with this specific type of wire?

    -The welds have a glossy appearance without the typical ripples seen in other types of welding.

Outlines

00:00

🔧 Welding with 1/16 Diameter Flux Core Wire

This paragraph introduces the topic of welding with 1/16 diameter flux core wire, addressing common questions about wire type and polarity. The speaker clarifies that a 'T' designator at the end of the wire indicates it's for DC positive use, and emphasizes checking the spec sheet for correct polarity and application. The video will demonstrate using Select 78 wire, suitable for seismic applications and specific materials, contrasting it with the previously used T11 wire. The speaker also explains the general rule for weld width in relation to electrode diameter and sets up the machine with appropriate parameters for the wire, including speed and voltage, and discusses the importance of correct drive rolls and fume extraction due to the flux's smoke.

05:00

🛠 Technique and Safety in Flux Core Welding

The second paragraph delves into the welding technique, emphasizing the importance of maintaining the correct work angle, side-to-side oscillation, and travel angle for optimal weld quality. The speaker describes the process of checking and cleaning the weld, looking for inconsistencies and porosity, and adjusting the welding speed and technique to correct any issues. The paragraph also touches on the wire's appearance and performance, noting its glossy finish and lack of typical ripples, and its suitability for seismic applications. The speaker shares personal experience with the wire and invites viewers to contribute their knowledge and experiences, concluding with an encouragement to improve with each weld and an invitation for feedback in the comments section.

Mindmap

Keywords

💡Flux Core Wire

Flux core wire is a type of welding consumable that has a core filled with flux material. The flux serves to protect the molten weld pool from atmospheric contamination and stabilize the arc. In the video, the presenter is using a 1/16 diameter flux core wire for self-shielded welding, which means it does not require an external shielding gas.

💡DC Negative

DC Negative refers to the polarity setting on a welding machine where the electrode is connected to the negative terminal of the power source. This is a common polarity used for certain types of welding processes, including some flux core welding. The video clarifies that not all flux core wires operate on DC negative, and the correct polarity should be checked on the wire's specification sheet.

💡T-Designator

The T-designator is a classification for flux core wires that indicates the type of current and polarity they are designed to work with. In the script, T-3, T-4, and T-6 are mentioned as being suitable for DC positive, which is important for welders to know to ensure they are using the correct wire for their welding machine's polarity.

💡Seismic Applications

Seismic applications refer to the use of materials and structures that are designed to withstand seismic activity, such as earthquakes. The video discusses using a specific flux core wire, Select 78, which is suitable for seismic applications due to its ability to handle cyclically loaded structures, like bridges and buildings.

💡3F Position

The 3F position is a welding term that refers to a vertical-up welding position, where the weld is performed on the top side of a vertical joint. The video mentions running a weld in the 3F position, which is a challenging position that requires careful technique and control of the welding parameters.

💡Filler Weld

A filler weld is a type of welding used to join two pieces of metal by adding additional material to the joint. In the video, the presenter is running a filler weld on a T-joint setup, which is a common type of joint in structural welding where two pieces of metal meet at a right angle.

💡Electrode Diameter

Electrode diameter refers to the size of the wire or rod used in welding. The video script discusses the difference between using a 1/16 diameter wire versus the more common 0.045 diameter wire, and how the weld width should be approximately five to six times the diameter of the electrode to ensure proper fusion and weld quality.

💡Stickout

Stickout is the distance from the contact tip of the welding torch to the workpiece. The video emphasizes the importance of maintaining the correct stickout, which is recommended to be between 3/4 to one inch, to allow the flux in the wire to preheat and protect the weld pool effectively.

💡Fume Extraction

Fume extraction is the process of removing harmful fumes and smoke produced during welding. The script mentions the importance of using fume extractors when welding with flux core wire, especially indoors, to protect the welder from inhaling potentially harmful fumes.

💡Weld Inspection

Weld inspection is the process of examining a weld to ensure it meets quality standards, checking for proper fusion and absence of defects like porosity. The video script describes the weld inspection process after completing the weld, using a wire brush to clean the weld and checking for consistency and quality in the weld bead.

💡Globular Transfer

Globular transfer is a type of metal transfer in welding where the molten metal forms large droplets that transfer to the workpiece. The video mentions that the flux core wire used exhibits globular transfer, which can result in some spatter and requires a slower, more methodical welding technique.

💡Travel Angle

Travel angle is the angle at which the welder moves the welding torch along the weld joint. The script describes maintaining a 10 to 15-degree downward travel angle to control the weld puddle and ensure proper fusion, which is crucial for the quality of the weld in the 3F position.

Highlights

Introduction to running 1/16 diameter flux core wire for self-shielded welding.

Clarification on the use of flux core wire with a 'T' designation for DC positive polarity.

Explanation of the difference between 0.045 diameter and 1/16 diameter flux core wires.

Rule of thumb for weld width being 5-6 times the electrode diameter.

Setting up the machine with Select 78 wire for seismic applications.

The importance of checking the spec sheet for correct polarity and application.

Demonstration of the recommended stick out for the 1/16 flux core wire.

Use of fume extractors for safety during welding with flux core wire.

Technique discussion: maintaining a 45-degree work angle and 50% weld distribution on each plate.

The significance of staying in the center of the puddle and the methodical welding process.

Adjustments in technique for better weld consistency and quality.

Inspection and cleaning of the weld to ensure proper fusion and absence of porosity.

The use of a second and third pass to improve weld appearance and quality.

Tips on maintaining the correct contact tip to work distance and travel angle.

Characteristics of the T6 flux core wire's glossy appearance and lack of typical ripples.

Discussion on the wire's suitability for seismic applications and cyclically loaded structures.

Recommendation for further research on wire codes and applications in bridge construction.

Personal experience with the wire dating back to 2010 and its advantages in out-of-position welding.

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