20 gauge Welding test

[elebub]

Kemppi MinarcMig 150
0.8mm wire
10 lpm Argon mix gas flow
20 gauge mild steel

Top dial is arc length trimmer - clockwise=longer/hotter
Bottom dial is metal thickness

This is just one set of many test pieces since I bought the machine. Started off by using 0.6mm wire but got fustrated trying to find an optimum setting where I could get decent penetration. Changed the wire to 0.8mm, which is what the sheet thickness dial is based on, and got on much better penetration-wise. Still looks like pidgeon do-do, HELP.

Andy

 

[Hitch]

When you tack the bits together, leave a bit of a gap, say 1mm or so. The welder should be about right where you have it, and try that. The gap will allow for penetration on the lower settings, which gives you a bit more time to control the weld pool.

 

[elebub]

Thanks for the reply Hitch.
I did try the gap method Saturday using intergrips and as you can see I cocked that up as well. Do I need to turn the wick down when using a gap? The test pieces either side were trying to replicate Malcolms video i.e. three tack welds and stitching inbetween. 4 was trying to weave until I hooked it into the rough on the last bit and 1a was a "straight" line attempt. What I cannot get my head around is torch speed. How on earth did Malcolm take 16 seconds to do that bead of welding without burning his workshop down or at the very least distort the metal out of all recognition?

 

[Hitch]

The gap looks a tab on the wide side to be honest.

You shouldnt need a weave on that, one other method for practice, raise one end up, say about a 1:5 slope, and weld towards the lower end.

As for speed, Take your finger, and run it along the short side of a piece of a4 paper.... i reckon it would take about 20 seconds to 'weld' it.
What do you reckon?

 

[weldequip]

Still reckon you'd be better with 0.6mm wire instead of 0.8mm but I think your main problem is that you are 'pointing & stabbing' with one hand. Try both hands, one on the trigger (obviously) but the other steadying the back of the torch, and try and maintain a steady distance from the job... around 4-5mm
weldequip

 

[elebub]

Will do the exercises as you suggest, hitch, and post the results as soon as I can but certainly at the weekend.

Jeez, weldequip, thats scary that you can tell from the welds that I was using one hand. Will use both in future.

The pictures are my best results using 0.6mm wire when I first got the machine. I was in uncharted territory as the machine is optimised for 0.8 wire and the manual just says set the metal thickness up slightly for 0.6 and down for 0.9-1mm. Did not help that the wire feed was somewhat erratic until I discovered that the 5kg reel was snagging the enclosure door. Emailed Kemppi and they told me to make sure that the 5kg reels were, quote, "no more than 60mm wide, the euro standard being 55mm" err, thats not in the manual. The A18 Weldability reel was wider than 60mm so when I changed it for a mini reel the feed was nice and smooth.

As you say weldequip I should get used to using 0.6 wire as most of my welding will be on E30 Beemer panels some of which are 22g. It might give me more latitude with the torch speed.

Thanks again lads, this really is the Open University of Welding.

 

[Sparkey]

Elebub hon, that wasn't scary that weldequip saw you were welding with one hand only!!! they're all over the place! (your welds i mean) i strongly suggest to use both hands and take your time to look at your weldpool... when you have a small gap between those practise parts it's also easier to see where you have to go... if you look well you should see the sparks bounce off in a straight line in the gap, thats where you have to go! and ofcourse your hands will get steadier after some practice!
keep it up!! Sparkey

 

[malcolm]

You'd be surprised at how much easier it is to practice on 1.5mm or thicker. It's much more forgiving, and when you get neat at that the thinner stuff is easier to do as well.

 

[Sparkey]

It's funny to see that people always are trying to make it harder for themselves!!! they take the thinnest practise material they can find!! sjeese, get yourself a big ol' chunk of steel and fire away at it!
Sparkey

 

[elebub]

Hi Sparkey

I accept your point, but there is a school of thought that says if you are going to be welding car body panels you might as well bite the bullet and just practice, practice, practice and then, just when you think you have got it - practice some more. Nothing worthwhile was ever achieved by being afraid of failure.

So watch this space, it may be a comedy of errors but I WILL get there.

Andy

 

[Stuggi]

Or you could do as me, get a car with thick panels to start with, and then every time you need a patch, you weld in a 1,5 mm sheet

 

[English Steve]

Thats the good bit about Landrover restos - 3mm thick steel chassis repairs

 

[Sparkey]

Ofcourse you will get there, elebub!! Now that's the spirit!!!! keep it up!!! Sparkey

 

[Stuggi]

Thats the good bit about Landrover restos - 3mm thick steel chassis repairs

Bloody hell, and I who thought the 1,5mm on my VW was thick.

 

[Johnny™]

Bloody hell, and I who thought the 1,5mm on my VW was thick.

i was gonna say "buy yourself a decent car like a Vdub", no more thin metal probs, just rust

keep it up looks like your getting better already. When you dial in the welder and get that hand steadier itll be a breeze

 

[Stuggi]

I just got feed up with the VW's "thin shell". The luggage compartment floor was really flimsy, and still over 1mm thick. For some odd reason, I could bend and shape the rusty piece I cut out, but the replacement 1,5 mm sheet didn't bend at all, and the original had all that intricate folding etc.

 

[Fixer]

My capri is made of the thinnest metal ive ever seen on a car, which is why I went straight to practising on 1mm and tbh, and its coming along o.k since I found this forum.

I don't like to spread bad advice (since I'm a begginer) but I found I like to look ahead ie. where I'm going and just keep glancing back for a second at the pool and arc lenth.
I spend around half the time looking at the ploted course about an inch ahead of the pool and the other half whaching the weld and I'm getting totaly acceptable results.

That said, I do practise on off cuts before almost every weld on the car lol

I was welding some patches in the boot floor and set light to the old gal the other day...stopped it with shielding gas tho but hey aren't old cars fun lol