Otto Nobedder wrote:Peter, my response was aimed at the idea of the capacity to do aluminum at some future date, so I didn't hit at the task at hand.
Talking of which I've produced this image to show the welding task required.
So the task (in imperial units) is to weld a supplied stainless steel sheet most likely supplied as a coil, thickness 0.8mm to 1.0mm (0.031" to 0.039") of length of about 10 metres (yards) length and up to 1.5 metres (yards) high.
The sheet has first to be slid into the custom bead rolling gear before then it is welded in situ so that means the weld has to be done vertically.
I think you call this kind of weld a butt seam weld but I'm pretty sure I can't afford one of those professional seam welding machines. Don't know how much they are but since I'd have to ask that's a sure sign that I can't afford one.
Ideally I'd want the welding gear to be reasonably portable so that I can load it up in a van and move it to where the job is being done. Whilst there might be room in my back garden to do this job, I don't think the neighbours would be too happy about it, so I'd have to hire a small light industrial premises to get the job done, or maybe a large double garage would be big enough. Well let's not worry about that now. The main point is that I can't load up any really heavy equipment in a hired van myself. So all the kit for the job has to be portable.
Otto Nobedder wrote: When I weld 16 ga stainless (usually in short stitches, though the answer still applies),
On stitch welding, if the required end result is a continuous seam weld, after welding the stitches, does one revisit the weld and weld in between the stitches?
How small can one make the stitches and the distance between them assuming thickness 0.8mm to 1.0mm (0.031" to 0.039") .
I got praise aged 7 for my very neat stitching at primary school so my inclination might be to stitch small, or at least as small as my eyesight would allow these days (is there anything to be gained by wearing magnifying glasses while doing stitch welding?) but there must be a limit how small the stitches can be and how close together you can stitch without the stitches running into each other and you end up with a continuous seam weld, right?
So how small can the stitches be? If the thickness of the sheet was "X" how small could the length of the stitches be - 2X, 3X, 5X, 7X, 10X, 15X, 20X, what? Likewise what's the smallest distance between stitches in X?
Otto Nobedder wrote: I'm not above 30A, expect maybe briefly to establish the initial puddle. I don't have pulse features currently, but if I did, the effective/average current would still be as low, so I'd expect a 160A machine to be able to do it in one go. I'd doubt even the torch will get too hot to handle.
OK.
Otto Nobedder wrote:Add to that, this is not a weld that can be done in one go. To minimize distortion, you'll be skipping around a bit for lots of short natural pauses, as well as the reasons you mentioned. I'll stop often to let what I'm working on cool, get a cup of coffee, or the other obvius break that results from too much coffee...
Steve S
Define "skipping around" please.
On minimizing distortion, I'd like to ask for more information about the use of a copper backing plate.
First to quote what the
WeldingTipsandTricks.com: Welding Sheet metal Video - How to make an invisible weld
The welder begins by doing something interesting that a lot of welders are not aware of...
He uses a small piece of copper sheet for backing.
Vise grip type sheet metal clamps are used to hold everything together and pulse tig is used to weld. You can count the pulses and its exactly 3pps or 3 pulses per second. Personally, I hate to weld with low frequency pulsing like this. It drives me nuts. I much prefer to set the pulse frequency to around 30 pps. That way my eyes do not have time to adjust between pulses. You still get the benefit of reduced heat input and agitation of the weld puddle without the eye strain and headache.
Anyway back to the part about the copper.
Sheet metal Copper backing does 2 things:
1. It draws heat out of the metal you are welding (if it is in close contact like with a chill block)
2. and it also traps argon in the weld puddle area. The back side of the weld on sheet metal gets hot and molten and needs shielding gas too.
Argon is actually absorbed into the molten metal, but gets squeezed out the back side upon solidification.
That small amount of argon on the back side of a sheet metal weld prevents excessive oxidation and allows the puddle to be a little bit cleaner and actually lets the puddle be more fluid because of less oxides floating around.
Many have mentioned to me the issue of distortion in welding thin stainless steel sheet and I so wanted to ask about using a copper backing plate, not only to keep oxygen out of the back side of the weld but to use to help take heat out of the sheet near the weld.
The guy in the video doing the invisible welding used a copper backing sheet / strip - maybe 6cm (2") wide and maybe 1mm 0.039" thick.
For a long straight weld I presume I will need a long straight copper backing strip, right?
If this welder had a thicker piece of copper like about ¼” thick, the weld would look even better. The good thing about using thin copper for backing for sheet metal joints is that you can form it to fit contours and can even tape in to the back side of a joint.
One caution….A little piece of copper like this one will get hot enough to burn you really quick. All the heat it absorbs from the weld is just waiting to make you holler if you pick it up too quick. So use copper backup for welding sheet metal.....but be careful.
No need to fit contours in my case and I'll be clamping the sheets together for the weld so no tape required.
Thicker is better presumably because thicker copper would take more heat out, help keep the sheet cool and reducing distortion, right?
I've seen 50mm x 10mm copper bar for sale but not from welding supply shops, on Ebay actually.
So that's 10mm thick or 0.4" which is thicker than the tipped 1/4" which I presume should be plenty thick enough, right?
Would that size of copper backing be suitable or would I be better with something wider / thinner / thicker?
I am curious as to why I don't see copper backing plates advertised as for sale by welding supply companies.
Why not? Why are a lot of welders not aware of copper sheet for backing?
Is copper backing sheet until recently an invisible-welder's professional trade secret, that the mass of welders don't know about, are not seeking copper to buy to use, that not even welding supply companies know about as yet, so that's why you don't see copper backing sheet sold as a welding accessory?
Where do expert sheet metal welders buy your copper backing plates and what size do they use? Does anyone supply copper bar specifically for the purpose of welding backing plate and what, if any, is the standard thickness of copper used?
Also what do you do to stop the copper backing plate melting and getting welded on the to the work piece?
Is it just a question of making sure the copper is dirty / oxidised or does the copper never get hot enough because it conducts heat away so fast even if in direct contact with the weld puddle or what?
I notice that in the video, the guy's copper backing plate has a little ridge in it. Is that relevant?
Do you need a small gap to keep the copper plate off the welding puddle but then how do you make sure the copper contacts the sheet either side of the puddle for good cooling but not the puddle itself?