1/16" Seismic Flux Core Welding | Vertical 3F

Weld.com
20 Dec 201909:15

TLDRIn this welding tutorial, the host demonstrates the use of 1/16" diameter flux core wire for seismic applications, focusing on vertical 3F welding. He clarifies the DC polarity for different flux core wires, explains the importance of checking specifications, and sets up the machine with 78 wire for seismic materials. The video provides tips on welding technique, including electrode diameter to weld width ratio, work angle, and maintaining the correct distance and angle for optimal results. The host also emphasizes safety with fume extraction and proper technique to achieve a strong, glossy weld suitable for cyclically loaded structures.

Takeaways

  • 😀 The video demonstrates welding with 1/16 inch diameter flux core wire, which is self-shielded and suitable for seismic applications.
  • 🔧 There is a 'T' designation on flux core wires that indicates polarity requirements; T3, T4, and T6 are for DC positive.
  • 🌐 The specific wire used in the video, Select 78, is designed for 3/4 inch plate and is ideal for seismic applications due to its cyclic load resistance.
  • 🔢 A general rule for welding is that the weld width should be 5 to 6 times the diameter of the electrode being used.
  • 🛠️ The video covers setting up the welding machine with the correct parameters: 170 inches per minute and 18 to 19 volts for the Select 78 wire.
  • 👷‍♂️ Proper drive rolls for the 1/16 inch wire are essential for the wire feeder to function correctly.
  • 🌫️ Fume extraction is highly recommended when welding indoors with flux core wires to avoid inhaling harmful fumes.
  • 🛑 It's important to maintain a safe distance and avoid standing in the path of fume extraction to prevent inhaling smoke.
  • 💻 The welding technique involves a 45-degree work angle, staying in the center of the puddle, and a slow, methodical process.
  • 📏 Maintaining a consistent travel angle of 10 to 15 degrees and a contact tip to work distance of 3/4 to 1 inch is crucial for quality welds.
  • 🔄 Post-weld inspection is necessary to check for proper fusion and absence of porosity, and any inconsistencies may require additional passes.
  • 📚 The wire used is often classified under D18 and possibly D15 for specific structural steel and bridge codes, indicating its suitability for seismic and cyclic load applications.

Q & A

  • What type of welding wire is being discussed in the video?

    -The video discusses 1/16 inch diameter flux core welding wire, specifically designed for seismic applications and self-shielded welding processes.

  • What is the 'T' designator in flux core wire and what does it signify?

    -The 'T' designator at the end of flux core wire indicates the polarity requirements. T3, T4, and T6 are all DC positive, and it's important to check the specification sheet to ensure the correct polarity for the application.

  • What is the difference between the 0.045 diameter wire and the 1/16 diameter wire mentioned in the video?

    -The 0.045 diameter wire is commonly used in the shop, while the 1/16 diameter wire is a larger 'big boy' wire used for specific applications, such as welding thicker materials like three-quarter-inch plate.

  • What is the recommended weld width when using the 1/16 diameter wire?

    -The recommended weld width is about five to six times the diameter of the electrode, which in this case would be approximately five-sixteenths to about 3/8 inches wide.

  • What is the purpose of the wire discussed in the video and in what applications is it typically used?

    -The wire is designed for seismic applications, shipbuilding, offshore rigs, and any cyclically loaded structure such as bridges and buildings. It is also used in Florida for launch pad construction.

  • What are the recommended settings for welding with the 1/16 diameter wire?

    -The recommended settings are to run at about 170 inches per minute and 18 to 19 volts, although the presenter found that 185 inches per minute and 19 volts worked well for them.

  • Why is fume extraction important when welding with flux core wire?

    -Fume extraction is important to capture the smoke and fumes produced during welding, which can be harmful if inhaled. It is especially recommended when welding indoors or in confined spaces.

  • What is the recommended work angle for welding with the 1/16 diameter wire?

    -The recommended work angle is roughly 45 degrees, which is dead center between the two plates being welded, to ensure an even distribution of the weld on both parts.

  • How should the welder maintain the travel angle and stick out distance while welding?

    -The welder should maintain a 10 to 15-degree downward drag angle and a stick out distance of 3/4 to 1 inch from the contact tip to the work, adjusting the wrist and forearm as needed to keep these angles consistent.

  • What is the appearance of the weld made with the 1/16 diameter wire and why is it different?

    -The weld has a more glossy appearance without the typical ripples seen in other types of welding. This is due to the globular transfer and thicker slag, which also makes it suitable for out-of-position welding.

  • How does the presenter address the issue of the ball on the end of the weld that makes arc starting difficult?

    -The presenter suggests terminating the weld about 3/4 of the way up and then stopping the next pass about halfway to show the profile of all three welds and to avoid the difficulty of starting the arc on the ball.

Outlines

00:00

🔧 Welding with 1/16 Diameter Flux Core Wire

The script introduces a tutorial on welding with 1/16 diameter flux core wire, addressing previous questions about wire polarity and the 'T' designation on flux core wires, which indicates DC positive use. The video will use a specific wire, Select 78, suitable for seismic applications and thick materials. The presenter explains the importance of checking specifications for correct polarity and application. A visual comparison between 0.045 diameter and 1/16 diameter wires is shown, and a rule of thumb for weld width relative to electrode diameter is provided. The setup for the welding machine is discussed, including wire feed speed and voltage, and the importance of using the correct drive rolls. Safety tips are given, emphasizing the need for fume extraction when welding indoors with flux core wires.

05:00

🛠 Technique and Tips for Flux Core Welding

This paragraph delves into the welding technique for flux core wires, focusing on work angle, side-to-side oscillation, and maintaining a consistent speed and distance. The welder demonstrates how to achieve a 3/8-inch weld width with the 1/16 wire, emphasizing the importance of staying in the center of the puddle and adjusting the wrist to maintain the correct angle as the work progresses. After completing a weld pass, the weld is inspected for proper fusion and porosity. The welder discusses the need for multiple passes to achieve a consistent bead profile and addresses the challenge of starting a new weld on the ball-shaped end of the previous pass. The video concludes with advice on maintaining a consistent technique, highlighting the wire's glossy appearance and suitability for seismic applications, and invites viewers to share their knowledge and experiences with the wire in bridge construction.

Mindmap

Keywords

💡Flux Core Wire

Flux core wire is a type of welding wire filled with flux, which is a compound that helps to clean the metal and protect the weld pool from contamination. In the video, the presenter uses a 1/16 diameter flux core wire for welding, which is a thicker wire than the typical 0.035 diameter they usually use. This type of wire is chosen for specific applications, such as seismic welding, where a stronger, more robust weld is required.

💡Self Shielded

Self-shielded welding refers to a process where the welding wire is capable of providing its own shielding gas, eliminating the need for an external gas supply. The video discusses the use of self-shielded flux core wire, which is suitable for various welding positions and materials, and is particularly highlighted as being used in DC positive polarity for the T3, T4, and T6 designators mentioned.

💡DC Positive

DC positive polarity in welding indicates that the electrode is connected to the positive terminal of the power source, and the workpiece is connected to the negative. This polarity is beneficial for certain types of welding, such as with flux core wires, as it helps in stabilizing the arc and controlling the weld pool. The script specifies that T3, T4, and T6 flux core wires are designed to be used with DC positive polarity.

💡Seismic Flux Core

Seismic flux core is a specific type of flux core wire designed for use in areas prone to seismic activity or where structures are subject to cyclic loading. The video mentions using Select 78, an 88 wire, which is suitable for seismic applications, particularly for welding thicker materials like 3/4 inch plate.

💡Vertical 3F Position

The term 'Vertical 3F position' refers to a welding position where the weld is performed on a vertical surface with the weld direction facing upwards. In the video, the presenter is welding a three-quarter-inch plate in this position, which requires specific techniques and settings on the welding equipment to ensure a quality weld.

💡Filler Weld

A filler weld is a type of welding used to join two pieces of metal by adding additional material, which fills the gap between them. The video script describes setting up a T-joint, which is a common configuration for a filler weld, and the process involves depositing weld material to create a joint that is strong and capable of withstanding the intended loads.

💡Wire Diameter

Wire diameter is a critical parameter in welding that affects the size and characteristics of the weld bead. The video contrasts the use of 0.035 diameter wire with the 1/16 diameter wire being used for the demonstration. The wire diameter determines the width of the weld, with the video suggesting a weld width of about five to six times the wire diameter for optimal results.

💡Stick Out

Stick out, also known as electrode extension, is the length of the welding wire that extends from the contact tip to the workpiece. The video recommends a stick out of 3/4 to one inch for the 1/16 diameter wire to allow the flux inside the wire to preheat and become active before entering the weld puddle.

💡Fume Extraction

Fume extraction is the process of removing harmful gases and particulates produced during welding. The script emphasizes the importance of using fume extractors when welding with flux core wire, especially indoors, to protect the welder from inhaling potentially harmful fumes.

💡Welding Technique

Welding technique encompasses the methods and motions used by a welder to create a quality weld. The video describes a technique involving a 45-degree work angle, side-to-side oscillation, and maintaining a specific distance and angle to ensure an even and strong weld. The presenter also discusses the importance of staying in the center of the puddle and adjusting the wrist and forearm to maintain the correct angle.

💡Slag

Slag is the non-metallic byproduct that forms on the surface of a weld as a result of the welding process. It protects the molten metal but must be removed after welding to inspect the weld quality. The video script mentions removing slag using a wire brush and conducting a weld inspection to check for proper fusion and absence of porosity.

Highlights

Introduction to running 1/16 diameter flux core wire for self-shielded welding.

Clarification on the use of flux core wire with DC polarity, emphasizing the 'T' designation for DC positive.

Explanation of the difference between 1/16 and 0.045 diameter wires for welding.

Rule of thumb for weld width in relation to electrode diameter.

Setting up the welding machine with the correct specifications for the wire.

Importance of using the correct drive rolls for the wire diameter.

Welding without a nozzle to demonstrate stick out and preheating of the flux.

Safety tips on fume extraction and avoiding inhalation of fumes during welding.

Technique discussion: maintaining a 45-degree work angle and side-to-side oscillation for even weld distribution.

The significance of staying in the center of the weld puddle and controlling the weld speed.

Adjusting wrist and forearm movements to maintain the correct welding angle.

Inspecting the weld for proper fusion and absence of porosity after completion.

Addressing inconsistencies in the weld bead profile and the approach to rectify them.

Demonstration of the termination technique for the final pass of the weld.

Characteristics of the weld appearance with T6 and T8 flux core wires.

Discussion on the suitability of the wire for seismic applications and cyclically loaded structures.

Recollection of the last time the presenter used this type of wire and its applications in the field.

Encouragement for viewers to share their experiences and knowledge about the wire in bridge applications.

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