1mm exhaust to 3mm flange

[Wightsparks]

Made an exhaust flange to mount a pipe to a silencer. The 1mm pipe passes through the 3mm flange, sticks out 5mm or so and is welded there. I have never welded anything less than 3mm so spent some time getting the machine (CWS 160i) set up, ended up running 70-75A wire speed of 3 (don't have the manual handy for the conversion).



I think this looks OK ?

The 2 problems I encountered on the job are that
1) with the lower power I don't seem to be able to see anything even with the helmet turned right down - I do have an overhead light so maybe it's that?

2) Possibly because of 1) but I don't think so, the weld seems to end up on one surface or the other but not in the joint as a nice fillet. Didn't have this problem welding the thicker stuff for the previous jobs. Will get a pic of the problem tomorrow

Suggestions please!

 

[Rocketman]

What I usually do on thick to thin is - set the mig up close to the setting for the thicker plate. When you hit it do so offset slightly into the thicker plate leaning into the thinner plate. Don't go snack in the middle or the thinner plate will get blown away.

I would guess why you aren't seeing much is usually wire feed too slow if it's actually welding something.

 

[EAZEE]

Agreed as Rocketman said. Set up for the thicker plate and flick the weld or weave on to the thinner stuff.

 

[Wightsparks]

Ok thanks, I'll set up some practice bits.

 

[Wightsparks]

Thanks @Rocketman and @EAZEE

This is a bit of 3mm welded to the 1mm can. 125-130A, WS 5. Which is just below 3mm spec on the machine.
I did 3 different ways of doing what you said to weld to the 3mm and weave to the 1mm, it certainly looks a lot better (allowing for my complete amateur status!) , penetration seems OK and no holes. Also With the stronger arc i can see what I am doing!

 

[Rocketman]

Glad you are getting on better. Practice, experimenting & asking questions/search past threads on the site. All my learning has only come from this site as far as mig goes and then going and trying it out myself in the garage.

 

[EAZEE]

Good job bud