Posted by Buzzman72 on December 01, 2011 at 18:54:57 from (74.129.197.170):
In Reply to: Remedial Welding Advice posted by George Rausch on December 01, 2011 at 17:47:20:
Are you able to SEE what you're welding? Before you take offense, realize that, if you're seeing what you're weding,you'll have a better idea of what is [and isn't] happening when you weld.
Just as you would with oxyacetylene welding, watch your puddle. Are the pieces of metal you're trying to join actually melting a bit into the puddle? If not, there are a couple of explanations. Maybe you're trying to weld metal that's simply too thick for .035" wire to be effective. [At the frame plant, we welded the Explorer frames with .045" wire...]Does the bead just lay on top of the metal with no fusion? Maybe you still don't have enough voltage to start melting the base metal, which is when fusion of the two pieces occurs.
My experience with flux-core wire is very limited...you ARE using flux core with no gas, aren't you? If not, that invites porosity into the welds...although you didn't mention porosity.
Without actually seeing either the results OR the process, the best advice is simply a SWAG [scientific wild-azz guess]. But I hope we gave you some ideas on where to begin to solve your problem.
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