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[Tiggy_dorset]

Speed and amperage. Gotta get comfy with those sort of things so you’ve got a smooth run. Used to fuse some stainless boxes but not as big as that only small ones.

Absolutely.
I tried many different ways (even different cup sizes), but finally think I have a method that works for me. The other guys have really nailed it, something to aspire to. They do their runs going across though, but I tried and found the easiest line for me is to draw the run from front, back towards me. Now I just need to cut the legs down on my stool and I might get a bit closer at being as good as them.
Purely out of interest, when it arrives I will try the gas lens and pyrex cup. Have used them before on other jobs, but couldn't say I noticed much difference from standard setup. With these boxes though I can see how it might possibly help things.

 

[Shox Dr]

Well... not quite welding, but this is my best autogenous(fusing) work thus far.

I'm sure most of us have fused brackets and little titbits, easy yeah? I thought so too, but to fuse up whole units to a high standard is quite a challenge as I discovered. A diffent kind of skill is needed in my opinion. After 2 weeks of these boxes I think I have finally got it... Only another 6000 boxes to go

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Lovely work, as you say far from easy. Fitup has to be perfect. What set are you using. I love the microtak function on the kemppi for tacking up stuff like that.

 

[Tiggy_dorset]

Lovely work, as you say far from easy. Fitup has to be perfect. What set are you using. I love the microtak function on the kemppi for tacking up stuff like that.

Im using just a simple 180 Jasic. The company I am working for at the moment seem to be a big fan of Jasics having bought a few lately (the day I arraived, they pulled one straight out of the box for me). Doesn't mean they are cheap though, they are into Lincolns and other higher end stuff... Hmm that must be why the other guys are so good eh

 

[HughF]

Im using just a simple 180 Jasic. The company I am working for at the moment seem to be a big fan of Jasics having bought a few lately (the day I arraived, they pulled one straight out of the box for me). Doesn't mean they are cheap though, they are into Lincolns and other higher end stuff... Hmm that must be why the other guys are so good eh

Nice job on those fused boxes there mate... reminds me of my days at priest's doing those little boxes with the spout sticking out

 

[Liquid Metal]

That FCAW looks factory bud.

Oops, my bad!! Wasnt flux core, was good old 4mm Esab 38.00 iron powders

That part wasnt the part that was welded with flux core, that was on a different job

 

[Liquid Metal]

Doesn't it just.
Looks like a bought one!

Not sure id call the place a factory, although i guess it is... More along the lines of a comedy club mixed with a prison camp

 

[Richard.]

Oops, my bad!! Wasnt flux core, was good old 4mm Esab 38.00 iron powders

That part wasnt the part that was welded with flux core, that was on a different job

Errr you sure??
That’s an awfully long continuous run from an electrode. Looks rutile FC to me.

 

[Liquid Metal]

Errr you sure??
That’s an awfully long continuous run from an electrode. Looks rutile FC to me.

Nope am sure of it. It is a 6mmplate rolled into a 600mm (?) diameter tube to make a roof access hatch for a small silo. The lip around the edge is only 120mm wide and 10mm thick.
The inside of it is set up as a corner joint with a 1-2mm gap welded in 2 passes with vodex 3.2mm root then capped with a 4mm filling out to a full fillet, then secondly welding the outside with iron powder.
Does look a bit bigger in the photo than it actually is, maybe due to perspective from the angle of the photo and not much to compare to size? Bit like the pipe in the other photo, its a 3" prepped and cut into a 4" at an angle.

The iron powders are 450mm long and get a good long runout at 195-200amps with a bit of an angle and not hanging about, giving a nice flat bead too. Being nice and warm still from welding the inside helps too.

 

[Liquid Metal]

Are they 4mm OK 48.00

Yes 4mm, but No not low hys. Definitely 7024 iron powders.
The esab number wasnt 38.00 it was 33.80 just checked a pack in the garage

 

[M K]

Some ally induction pipes for mini F56

 

[Richard.]

Love the consistency there mk. Some lovely aluminium welding there.

 

[Gizmo.Y]

Some ally induction pipes for mini F56

I always wondered about the Airtec Tags. Are they welded or bonded on?

 

[M K]

Tags are drilled puddle welded then D/A’d off

 

[Tigman]

nice !

 

[Ian James]

I know this thread has been running a while so to restart it it here is a tig fusion weld mild steel plate to bright drawn bar @ 100 amps done by a amiter