VERTICAL Flux Core Groove Weld | D1.1 Weld Test | 3G Uphill
TLDRIn this welding tutorial, the host demonstrates a vertical flux core arc weld using a self-shielded, 3G uphill technique on a single V butt joint. He explains the importance of reference lines, joint preparation, and bevel angles. The video covers the welding process from setup to finish, including tips to avoid porosity and proper cleaning and repair techniques. The host emphasizes the significance of maintaining the right angles and ensuring a quality weld, concluding with a successful demonstration.
Takeaways
- 🔧 The video demonstrates flux core arc welding with a self-shielded variety, specifically for a complete joint penetration through AWS D1.1 in the 3G (vertical uphill) position.
- 📏 The importance of the reference line is highlighted for joint preparation, with the backing strip placed on the opposite side of the arrow indicating the joint preparation site.
- 🔨 A single V butt joint with a quarter-inch root opening and a 45-degree included angle is used, requiring each plate to be beveled at 22 and 1/2 degrees.
- 📝 The welding symbol is explained, including the note section for additional information such as weld sequence, hold points, and processes that may not be covered by standard symbols.
- ⚒ The necessity of proper joint fit-up is discussed, including maintaining a quarter-inch root opening and ensuring the plates are clean of mill scale to avoid impurities in the weld.
- 🛠️ The process of setting up the welding fixture for the 3G position is shown, emphasizing the need for correct bevel angles and plate positioning.
- 🔥 Tips for mitigating porosity in the weld, such as clipping the wire for better arc initiation and maintaining the correct contact tip to work distance, are provided.
- 👷♂️ The video includes a practical demonstration of how to fix welding errors, such as poor feeding issues, by cleaning the groove and resetting the drive tension rolls.
- 🛑 The significance of checking equipment, such as driver tension rolls, before starting a weld is underscored to prevent mistakes and ensure quality.
- 💡 The technique of using a work angle while welding is introduced to improve weld flow and positioning, with specific angles suggested for different passes.
- 🏗️ The final weld appearance is evaluated against criteria such as smooth tie-ins, absence of porosity, and weld reinforcement within the specified limits of flush to 1/8 inch.
- 👍 The video concludes with a positive outcome, emphasizing the continuous improvement in welding skills and the importance of learning from mistakes.
Q & A
What type of welding is being demonstrated in the video?
-The video demonstrates flux core arc welding, specifically the self-shielded variety, in the 3G (vertical) uphill position.
What is the purpose of the reference line in the welding setup?
-The reference line is crucial as it serves as the basis for all information related to the welding process. It is used to determine the placement of the backing strip and the joint preparation.
What is the angle of the single V groove joint being used in the video?
-The single V groove joint has a 45-degree included angle, which means each plate is beveled at 22 and 1/2 degrees to achieve this angle when joined.
Why is it important to have a tail in the welding symbol?
-The tail in the welding symbol is used to provide additional information that may not be covered by standard symbols or notes. It can include weld sequence, hold points, and specific weld processes.
What is the significance of the bevel angle tolerance in welding?
-The bevel angle tolerance ensures that the weld preparation is within acceptable limits, preventing issues such as poor penetration or excessive reinforcement, which can affect the quality and integrity of the weld.
How does the welder ensure the root opening is consistent during the setup?
-The welder uses a piece of quarter-inch thick steel to set both ends of the backing strip, ensuring equal spacing and a consistent root opening of approximately a quarter-inch.
Why is it recommended to clip the wire before starting the weld?
-Clipping the wire improves arc initiation characteristics, reducing the chances of popping and kicking back, which can disrupt the shielding gas and lead to poor weld quality.
What is the recommended contact tip to work distance for the wire used in the video?
-The recommended contact tip to work distance for the wire used in the video is 5/8 inches.
Why does the welder rotate the gun during different passes?
-Rotating the gun helps to direct the weld flow better and ensures that the weld ties into the previous pass effectively, preventing issues such as undercut or excessive buildup.
How does the welder ensure the final cap of the weld is within the specified limits?
-The welder aims to have the final cap at least flush to 1/8 inch, using the edge of the plate as a marker and maintaining a 10 to 15-degree work angle to stack each pass against the previous one.
What is the importance of checking the weld with a weld reinforcement gauge?
-Using a weld reinforcement gauge helps to verify that the weld reinforcement is within the specified limits, ensuring the weld's quality and compliance with industry standards.
Outlines
🛠️ Introduction to Flux Core Arc Welding
This paragraph introduces the topic of the video, which is flux core arc welding using self-shielded procedures. The speaker discusses the process of creating a complete joint penetration through the American Welding Society's SD 1.1 standard in the 3G position. The video will also cover drawing the welding symbol and preparing the welding area. The fit up of two plates for a single V butt joint is explained, with a focus on the reference line and joint preparation, including beveling the plates at a 22.5-degree angle to achieve a 45-degree included angle. The importance of the reference line in welding is emphasized, as it is the basis for all information needed for the weldment or fixture.
🔨 Setting Up and Tack Welding the Joint
The speaker proceeds to set up the welding project, including adjusting the backing strip and ensuring a quarter-inch root opening with a 45-degree included angle. The process of tack welding the plates in place is described, with attention to maintaining the correct spacing and preventing warping. The importance of cleaning the area with a wire wheel to remove mill scale and contaminants is highlighted to ensure a clean surface for welding. The video also addresses a common issue of porosity at the start of the weld and offers solutions such as clipping the wire for better arc initiation and maintaining the correct contact tip to work distance.
🔧 Welding Process and Troubleshooting
The paragraph details the welding process, starting with the root pass and progressing through multiple passes to build up the weld. The speaker discusses personal preferences for welding techniques, such as running stringers and inner passes, to create a solid foundation for the final cap. The importance of staying within the specified weld reinforcement limits is emphasized, with the cap not exceeding 1/8 inch and being at least flush. The paragraph also includes a troubleshooting segment where the speaker corrects a mistake made during the welding process due to improper drive tension roll settings, demonstrating how to fix the issue and resuming the welding process.
🎖️ Completing the Weld and Quality Check
In the final paragraph, the speaker completes the welding process by putting in the final passes and preparing to cap the weld. The focus is on achieving a smooth and even appearance, with tight tie-ins and no visible defects such as porosity or undercut. The use of a weld reinforcement gauge is mentioned to ensure compliance with the specifications. The speaker also discusses the importance of the work angle when making each pass, to prevent the formation of humps in the weld. The video concludes with a quality check of the completed weld, confirming that it meets the required standards and showcasing a successful outcome.
Mindmap
Keywords
💡Flux Core Arc Welding
💡3G Position
💡Single V Butt Joint
💡Backing Strip
💡Welding Symbol
💡Bevel
💡Tack Weld
💡Weld Reinforcement
💡Cap Pass
💡Porosity
💡Welding Machine Settings
Highlights
Introduction to flux core arc welding using self-shielded variety for a complete joint penetration.
Explanation of the 3G (vertical uphill) welding position.
Importance of the reference line in joint preparation and its relation to arrow side and other side.
Description of joint preparation with a single V butt joint and vacuum.
Details on the 45-degree included angle and how to achieve it with 22.5-degree bevels on each plate.
Demonstration of how to properly set the bevel angle using a protractor.
Discussion on the necessity of cleaning the plates to remove mill scale before welding.
Technique for adjusting the backing strip and ensuring proper root opening.
Tack welding the plates together and ensuring no gaps for a tight fit.
Machine settings for welding with a 45 diameter wire, 160 inches per minute, and 19.5 volts.
Advice on wire clipping for better arc initiation to prevent porosity.
Importance of maintaining the correct contact tip to work distance.
The role of the nozzle in self-shielded flux core welding and its function in retaining the contact tip.
Troubleshooting poor feeding issues due to improper driver roll tension and the repair process.
Correcting mistakes by cleaning the groove and ensuring the use of the right grinding wheel.
Welding technique of running a stringer bead and the importance of a good tie-in.
Process of adding inner passes to build up the weld foundation for the final cap.
Final capping technique and ensuring the weld reinforcement is within the acceptable parameters.
Conclusion summarizing the successful outcome of the welding process and the importance of attention to detail.