Welding Profiled Tube

[f0xy]

After a bit of practicing with welding tubes (45mm CDS, 1.6mm Wall) that have been profiled to 90 degrees or there abouts, I am confident in getting decent smooth welds round the joint.

Although I attempted some lower angle welds (again profiled very tightly) but they did not go anywhere near as well as the straighter joints.

From the attached image, which would be the best way of welding round the profile? Downwards with the torch in position 1, going round and having the majority of the weld on the solid pipe, or position 2 going along the profile?

If neither is the proper way to do it, does anyone have any suggestions?

Thanks!

 

[Bsmith]

Mig welding.

Actually your drawing and pic show the cut pipe opposite ways but with bottom pic I would start at the top and weld downwards concentrating most of the heat onto the solid pipe and watch out for undercutting the cut one, same on other side, but you might have a slight prob at the bottom as it will be quite tight for getting the mig nozzle into. So long as you end up with a good strong weld with no undercut I don't think there is a proper way. Thing to also watch for will be heat distorting the solid pipe.

 

[f0xy]

So would I be right in saying undercutting would be caused by too much power/or/moving too slow?

I tried a few practice welds on two bits of pipe at similar angles, and concentrated on running the weld down the solid pipe, although the profiled pipe seemed to 'disappear' rather than join into the weld pool.

 

[Bsmith]

Yep undercutting, too much power or heat.
WFS could be a little low too but think as above.
Gosh, your pipe is only 1.6mm wall thickness, might be an idea of just tacks the whole way, you could then do a continuous weld over the tacks if you feel it needs it.

 

[pedrobedro]

1.6 wall should weld without resorting to a row of tacks. I would weld the join across the tube, down one side of the longer and then down the other from the opposite side. Weld on the solid tube and catch the edge of the cut tube, your joint looks plenty close enough to get them both at once. If you have a spare shroud squash one a bit to get in the tight corners or cut it back level with the end of your contact tip and turn the gas up a bit to get in the angles.

 

[Bsmith]

Got to agree with you pedrobedro, but for a fella new to mig, think tacks will ease the (edge burn away) prob for him.

 

[AstoN]

Is this foxy from cliosport?

Looks like your clio from the top pic...

If so, hello

 

[f0xy]

Certainly is matey!

Time to learn this useful skill

 

[AstoN]

I find its a neccessity if you own an older car. Whether just for fun/project stuff or if rust gets the better of certain bits.

I own a Ford now...

It'll become a zetec turbo'd xr3 cab this year though. Nut and bolt rebuild.