Welding Tips and Tricks

Hi all. I work as a welder in Wyoming and most of what I do revolves around stick and wire feed (dual shield, hardwire, etc.). Right now most of the work I do is oilfield related, but the mining industry out here is enormous as well. While a lot of the work they do is usually some sort of gas shielded fcaw you need to be able to pass both a 3g and 4g unlimited thickness test with 5/32 7018 as well. My concern is about 3G test, while this was something we had to pass when I went through school I can remember being dissatisfied with the results. It didn't seem to matter what adjustments I tried to make (amperage, arc control, arc length, electrode angle, speed, etc.) I always ended up with a larger bead with a bit of a crown. Im wondering if it's a manipulation thing or a combination of things? I would appreciate any wisdom you veterans might be willing to part with, thanks!

Welcome!

I know another "GentleBen" from the IPR forum. Could it be?

Steve S

GentleBen,
Welcome to the forum!! First of all good luck on your tests! I am assuming the 3G is SMAW with the 5/32 electrodes. I took my 3G 1" plate a week ago and used both 1/8" and 5/32" electrodes and passed. On a 1" test you will use stringers. I weaved until my third pass and stringers the remainder of the way. One "problem" I saw with several of us is the bottom is shallower than the middle and top. To combat this I simple slowed down at the bottom and sped up on top. Remember that per AWS D1.1 you are allowed 1/8" on the cover pass and if you look closely most documents have a +/- 1/16" tolerance which could possibly allow 5/32". I did find out that "technically" you can grind your test piece flat and send it in. It is late and I can't remember the technical reason why, I think is was something like nothing is said on height for a actual test.

I can't remember what amperage for sure I was using but think I was 105-110 amp for the 1/8" and 130-150 for the 5/32". I will run a test plate sometime this week, I "qualified" for my employer and now have to do it for business. Another thing I did was no manipulation of the electrode if I could help it. Hold a 5* push angle and you will be fine. I should have taken pics on the last test.
-Jonathan

Otto, sorry to disappoint but this is the only time I've ever used the handle GentleBen haha.

Jonathan,
Thanks for taking the time to drop some pointers! I immediately identified with what you said about being shallow on the bottom, I'll slow down a bit. Also you're amperage settings are a bit higher than mine and I was wondering if maybe I ought to turn it up a notch or two so I'll experiment with that as well.It makes sense that a little more amperage might make it easier to run some tight stringers, thanks again!
-Ben

Here are a few more but they might not work for you. I also set my gap a "loose" 1/4" to 5/32", again using the allowable tolerances given. A looser gap will allow you to bite into the corners of the bevel elimating the chances of slag entrapment. I also use one amperage setting for all but the cover pass. At that time I will determine if I feel I need to go up/down due to heat built up, weld bead build up or any irregularities.

I know for sure I was at 105 amps on the 1/8" but not 100% on the 5/32", will try to check that when I can. What amperage were you originally running?
-Jonathan

Yep 105 always works well for me with 1/8" and the 5/32" I have been no more or less than 125-130 amps.
-Ben