[PaulProe]

I am trying to weld a flange onto a 3" diameter tube. Both pieces are 18ga. I am having problems with the throat of the fillet weld being way too big. I believe the volts and feed is correct. I can't get the stick-out any closer because the tip shield hits the pieces.

Is there a way to get a small weld in a situation like this, when using a GMAW process?

Weld is not structural, strictly cosmetic. and right now, it isn't very cosmetic

I'd like to get a weld leg of around 1/8" It is coming out around 3/16 with the throat around 1/4" -convex I am using .025 wire and C25 gas Weld isn't burning thru and it borders on being pretty ropey

thanks for any tips you can throw my way

Paul

[sedanman]

Trim your nozzle or buy a tapered one. Run the smallest diameter wire you can find , .023.

[TheNovaMan]

How long is your stickout, and what settings are you using? What shielding gas, and what flow rate?

If you don't want to cut up your nozzle, you might get away with turning up the voltage. Check out this video for an extreme example of long stickout:
https://www.youtube.com/watch?v=zd8h4iCf4TY

[Poland308]

https://www.weldingsuppliesfromioc.com/ ... -ws-21t-37
Pointed gas nozzles help to get way deep into those tight corners.