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Welding Guidelines
General
This welding machine can utilize the Flux Cored Arc Welding
(FCAW) process or the Gas Metal Arc Welding (GMAW) process.
The weld must be protected (shielded) from contaminants in
the air while it is molten. The FCAW process uses a tubular wire
with a flux material inside. The flux creates a shielding gas when
melted. The GMAW process uses inert gas to shield the weld
while molten.
When current is produced by a transformer (welding machine)
and flows through the circuit to the weld wire, an arc is formed
between the end of the weld wire and the work piece. This arc
melts the wire and the work piece. The melted metal of the weld
wire flows into the molten crater and forms a bond with the work
piece as shown (Figure 7).
Nozzle
Shielding Gas
Slag
Weld
Crater
Figure 7 - Weld Components
Arc Welding Basics
Six basic techniques affect weld quality. These are: wire
selection, heat setting, weld angle, wire speed, travel speed,
and electrode extension. An understanding of these techniques
is necessary for effective welds.
Heat setting
The correct heat involves the adjustment of the welding
machine to the required setting. Heat or voltage is regulated by
a switch on the welder. The heat setting used depends on the
size (diameter) and type of wire, position of the weld, and the
thickness of the work piece. Consult specifications listed on the
welder. It is suggested that the welder practice with scrap metal
to adjust settings, and compare welds with Figure 8.
Contact Tip
Flux (Gasless only)
Wire
Work Piece
www.campbellhausfeld.com
Models: WG3080, WG3090 and WG4130
Base
Metal
Normal Heat,
Wire Speed,
Travel Speed
Heat Too Low
Heat Too High
Figure 8 - Weld Appearance
wire type and size
The correct choice of wire type involves a variety of factors,
such as welding position, work piece material type, thickness,
and condition of surface to be welded. The American Welding
Society, AWS, has set up certain requirements for each type of
wire.
FluX-Cored Wire
e - 7 0 t - gs
Weld strength, times 10,000 pounds per
square inch
Welding positions (0 for flat or horizontal, 1
for any position)
Tubular flux-cored wire
Flux type
AWS E71T-GS or E71T-11 is recommended for this welder.
solid Wire
er - 70 s - 6
Weld strength, times 1,000 PSI
Solid wire
Wire composition
ER-70S6 is recommended for this welder.
Travel Speed
Too Slow
Wire Speed Too Slow
Wire Speed
Too Fast
Travel
Speed
Too
Fast
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