Although not addressing welding methods directly, if you can change the way you bend up the pieces of the "box", you can greatly reduce the length of weld bead to make the finished part. Less weld length should = less chance of flaws! Current configuration gives 2 x (15 + 23 + 15) =106 in...

Quick and small update for anyone interested: we did try to mill the jig to an angle but the end result was not what we require. We actually made a small chamfer on the edge, so that the weld pool can "collapse" on it and take its shape, Meaning that our product will have a chamfer on the ...

I'm working now on improving the jig based on your suggestions, I will post updates once we have welded some more samples. But I wanted also to ask about grinding and polishing: given the strict requirements (fillet-like bead on the inside, good looking bead on the outside) what would you recommend ...

This was 1.2mm. For 0.8mm I would set to 34amps and use the peddle to adjust as I go. I also prefer a number 12 gas lense cup for these outside corner joints. I use the fupa cups from Jody’s weldmonger store. Sheared edge on 0.8 should be fine without deburring. You’re going to fully penetrate anyw...

I would go with sample 2 AND purge the inside. Purging it will help eliminate the weld bumps a little. The copper chill bars are great to help control distortion, but do nothing for eliminating contamination. After welding the outside, you could still come along the inside and "wash" the ...

Lack of purge in your case is why the inside looks poor. For 20ga stainless, you don't need much heat, and you should only use a thin filler wire. Honestly, if the fit is tight, you could simply run without filler and fuse the outside. With a back purge, you should see a very clean inside (especial...

If you want a super clean inside, then I would weld outside corners. I strongly encourage you to make a purge box and clamp it to the inside corner, run Argon on the interior while welding the outside. This will eliminate any contamination of the inside corner (which will be extremely difficult to ...

Hello everyone I hope you won’t mind my English, it is not my first language so please be patient :) My company is working on a new product which requires some very long corner joints, material is 20 ga stainless steel. (~0,80 mm for us Europeans :D ). It’s basically some sort of box, made with a “C...

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I'm an engineer writing from Italy, hoping to improve my knowledge in welding technologies with the help of this community!