Welding Question

[bob7four]

I am using a flux core welder (I know but no money in budget to buy a new welder) I notice that the spot welds seem small but when I try to get a bigger puddle it burns through the edge of the sheet metal that I am trying to butt weld. My question... is there something I should be doing differently? My speed off the spool is set at 1-1/2 or 2 for 18 ga material. Appreciate your suggestions. Thanks

 

[pishta]

put a copper backing under the weld area, like a bent flat copper pipe. The copper wont melt and the weld wont stick to the copper. Flux core welding 20-22g is almost impossible as it uses higher heat than gas welding. Also try just little spot welds. Welding up old rust headers with a flux core welder is about as effective as using a .45 on 'em. You can also vary the stick out of the wire and feed. That may give you a better chance of making some welds instead of some holes.

 

[coloradohill]

Take a look at this guys website. I’ve learned quite a bit from him.

Welding Tips and Tricks - TIG, MIG, Stick and a pantload of other info

 

[Mike69cuda]

Back in the day we gas welded lots of stuff like that with coat hangers. Worked pretty well after you got the hang of it. Just poor high school kids making do. I can still remember my mother hollering “ where are all the coat hangers” when we were doing a big project.

 

[jazak5]

I am using a flux core welder (I know but no money in budget to buy a new welder) I notice that the spot welds seem small but when I try to get a bigger puddle it burns through the edge of the sheet metal that I am trying to butt weld. My question... is there something I should be doing differently? My speed off the spool is set at 1-1/2 or 2 for 18 ga material. Appreciate your suggestions. Thanks

 

[TT5.9mag]

Best advice is to get some metal similar to what you will be welding and practice. Machine set up is the hardest part of welding. And you’re not doing yourself any favors using flux core. It’s a pain in the ***. But it can be done. My first thought is you need more wire speed but you’ll have to experiment with your machine.

 

[TT5.9mag]

Copper back up is a great suggestion. Also your local welding supply should have ceramic back up bar that has a sticky side and is easy to use.

 

[dano]

Look up the wire your using. There is inner shielded wire for specific purposes, like multiple pass or single, galvanized metal, thin gauge, etc. See what you have and if it will do what your asking. You mention speed but not heat range, might be too hot.

My dad can do plug welds that look like a cow pie but fully burned in. I blow holes in metal like I was using armor piercing bullets. He has way more practice and we're set up for MIG.

 

[Greasyfingers]

Wire size has a lot to do with it also. With a smaller wire there's less of a chance of too much heat to blow through the thin sheet metal.

 

[retroron]

I am using a flux core welder (I know but no money in budget to buy a new welder) I notice that the spot welds seem small but when I try to get a bigger puddle it burns through the edge of the sheet metal that I am trying to butt weld. My question... is there something I should be doing differently? My speed off the spool is set at 1-1/2 or 2 for 18 ga material. Appreciate your suggestions. Thanks

flux core is the not the best process for welding sheet metal. You would be much better off using solid core wire with a argon/co2gas shield to weld sheet metal. A good welding supply store in your area can set you up for a small cost. Your current welder should work just fine.