Welding Tips and Tricks

Hello, old guy from the Seattle area, with a fair amount of welding experience over the decades. No certs, but a good bit of experience repairing heavy equipment via stick welding, plus miscellaneous other dabbling. in my old age i have just treated myself to a new piece of gear, a new ESAB Rebel 205 ac/dc. My first inverter machine, first with a computer (I asked the local ESAB rep if he could send over a couple of ten-year-olds to show me how to use the computer, such things only being user-friendly and intuitive to their programmers . . . and to all modern kids!!).

Jody, I've been watching your videos for a month or so. Beautiful arc shots!! I just wish my old eyes could see the puddle (and the PATH!!) anywhere near that clearly (have to get the cataracts fixed soon; anybody done that?).

Anyway, I have a question arising from one of your MIG basics vids, Part 3, I think. In that one you describe a method of getting initial machine settings starting with calculating wirespeed from metal thickness and the "burn-off rate" for the various sizes of hard wire. Oh I know my new little ESAB has a Smart-MIG feature that will figure it all out, but I still will be using other machines. So I'd like to know first, is your "burn-off rate" the same thing as what other sources call "deposition rate"? Next, am I right in assuming that the rates you listed in that video only apply to solid steel wire sizes? In other words. your posted burn-off rate for .035" hard wire would not apply to no-gas flux core, or dual-shield, or aluminum (yeah, I even bought the Tweco spoolgun that goes with the ESAB!!)?? I tried to find the burn-off rate charts for those other types of wire, with no luck so far.

The project of the day is to finish building a cart for the new ESAB. Portability is key here. I'll want to roll the cart with the ESAB and all its gear out to my minivan, unload the stuff, followed by the empty cart, into the vehicle, reverse the process when I get to the jobsite, and be able to pull the cart over gravel or uneven ground. Thus the cart has to be fairly small, light yet strong (I'm making it from old bed-frame steel), and have large diameter wheels. Fun project. Makes ya feel sorry for people who can't weld!!

Welcome Seattle Smitty,

Jody doesn't actively participate in these forums, just FYI.

The wire-burn off he mentions is kinda of a mis-nomer because it will inevitably get confused with "wire burn off rate", measured in lbs/hour, and also "deposition rate" (as you have clearly shown), whose units are also lbs/hour.

But don't worry, here we can clear it up:

• the rate he mentions is more of a conversion-factor.
• It allows someone to estimate amperage based solely from WFS.

If the machine has actual WFS indicators (meaning explicitly, in IPM), you can use those multiplicative factors he lists together with the WFS, to roughly dial in your amperage (for a given CTWD), which is ultimately going to be determined in large part by the thickness of the steel you are trying to weld. And yes, those conversion rates are for solid steel wires only.

Like Jody mentions in either that video or another one, you yourself can calculate wire feed speed using just a timer and a tape measure in the event that the machine has no actual numbers for WFS.

Hello Smitty with and welcome. I can totally understand the need for youngsters with the computer controlled devices. I can also understand the problem with "old eyes". The only real way around them is to practice ... a lot and get a good hood. We have had several folks using old bed frames for building and hear complaints about their use. I don't think there is any kind of consistency with the making of the material used in bed frames...just my opinion. As far as the settings go, all machines have settings, all machines we use are welders ,,, the settings advised by the manufacturers are ball park numbers and will get you moving. Hope you have a great time and experience with the "new" type machine.
gramps

Thanks, Oscar. I've been using the stopwatch-and-tape measure for some time to get real wfs numbers for various welders and feeders. One additional measurement I record is input voltage, but then I generally forget to compare readings later on, duh.

Bill, a lot of welders think that bedframe is some cheapo "alloy X" made from random scrap. Well, talk to the blacksmiths and knife-makers. Bed frame is spring steel with 45-50 points of carbon; if you get one end red-hot and hold there for a bit, then quench, it will likely be "file-hard." Think about what's called for, light weight, because bedframes are shipped all over, plus the strength to resist big fat welders flopping down on the bed at day's end . . . that little .090"-.100" frame has to give and then spring back without taking a permanent bend as mild steel would. So how do you weld medium carbon steel? With pre-heat so the HAZ isn't quick-cooled by the metal on either side. I like bed-frame: light, strong, and FREE if you look around!!
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Seattle Smitty wrote:Thanks, Oscar. I've been using the stopwatch-and-tape measure for some time to get real wfs numbers for various welders and feeders. One additional measurement I record is input voltage, but then I generally forget to compare readings later on, duh.
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Seattle Smitty

One resource you might like, that I need to purchase as well, is "The Procedure Handbook for Arc Welding". It has all sorts of charts and values for different wire types, as well as suggestions for operating parameters for various positions.

Lincoln's Big Black Book, right? I got mine about forty five years ago, a long time given the rate of technological change, but the Black Book, like that other great old compendium, Machinery's Handbook, stays relevant indefinitely. But now that you mention it, I haven't picked up my copy in some time and am not sure where it is, my bad.

Seattle Smitty wrote:Lincoln's Big Black Book, right? I got mine about forty five years ago, a long time given the rate of technological change, but the Black Book, like that other great old compendium, Machinery's Handbook, stays relevant indefinitely. But now that you mention it, I haven't picked up my copy in some time and am not sure where it is, my bad.

Not sure what color it is, or has been. I need to get one myself. I haven't needed to yet since I can usually determine what I need via experimental/empirical/numerical-algebraic methods, but I'm sure there's plenty in there to learn.