basic guide to flux cored arc mig welding

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  • 8/10/2019 Basic Guide to Flux Cored Arc MIG Welding

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    Food Living Outside Play Technology Workshop

    Basic Guide to Flux Cored Arc Weldingby SLOMakerSpaceon October 8, 2014

    Table of Contents

    Basic Guide to Flux Cored Arc Welding .............................................................................................

    Intro: Basic Guide to Flux Cored Arc Welding ......................................................................................

    Step 1: Gather Necessary Equipment ...........................................................................................

    Step 2: Clean Your Metal ....................................................................................................

    Step 3: Cut Your Metal ......................................................................................................

    Step 4: Set Up Your Work Piece ...............................................................................................

    Step 5: Turn on Welder and Adjust Settings .......................................................................................

    Step 6: Tack-Weld the Work Piece .............................................................................................

    Step 7: Fill in the remaining areas with 'Bead' Welds ................................................................................ 1

    Step 8: Clean up your piece .................................................................................................. 1

    Step 9: Clean up the area .................................................................................................... 1

    Step 10: Profit! ............................................................................................................ 1

    Related Instructables ........................................................................................................ 1

    Advertisements ............................................................................................................... 1

    Comments ................................................................................................................ 1

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    Author:SLOMakerSpace SLO MakerSpace, Inc.

    SLO MakerSpace offers tools, training, and consultation services that enable community members to experiment with and master a wide variety of Makerskills. We are dedicated to the following values: Community We foster the development of a community of diverse people, at low cost, in a positiveenvironment; Collaboration/Education The sharing of knowledge and ideas is critical for personal and professional growth; Entrepreneurship We suppothe growth of new businesses through skill-building classes and consulting services

    Intro: Basic Guide to Flux Cored Arc WeldingHello and welcome to the SLO Makerspace guide to Flux Cored Arc Welding! This Instructable is intended to teach you how to use the Lincoln Weld Pak HD flux corearc welder. This machine is one of the most basic welders available on the market today and is known for being both user-friendly and cost efficient. Although there aseveral limitations as to what you can get away with welding on this machine, it is a great welder for beginners and is perfect for doing non-structural, ornamental

    welding.

    Here are some Weld Pack HD product specifications provided by Lincoln Electric:

    Welds mild steel with a gasless, flux core wire electrodeWelds up to 1/8 in. mild steelPlugs into household 115V, 20 amp outlet35-88 amps outputCold contactor safety feature keeps welding wire electrically cold until the gun trigger is pressed

    For more information in regards to this particular welder, please read the operator's manual: HERE

    The first and most important thing to consider while using this machine is... you guessed it, SAFETY! Not only is the electricity required for arc welding extremely hot, it also generates dangerous UV light that can easily damage your eyes if you look directly at it. This is why you should always use the proper Personal ProtectionEquipment (PPE) while working on your welding project. This includes, but is not limited to: safety glasses, leather welding jacket, welding gloves, and of course, thewelding mask (also known as a welding hood). It also really helps if you have long pants and close-toed shoes. Flux Cored Arc Welding (FCAW) is known to generatelots of sparks that can easily burn any unprotected areas of your body, so cover up! These sparks can also easily start a fire so any flammable materials should be keat a reasonable distance from the welding area.

    That being said, welding can be a fun and exciting way to make things out of metal and after a bit of practice, there is endless potential to make some really cool stufflets get started!

    http://www.lincolnelectric.com/assets/servicenavigator-public/lincoln3/imt768.pdfhttp://www.slomakerspace.com/http://member/SLOMakerSpace/http://member/SLOMakerSpace/
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    Step 1:Gather Necessary EquipmentBefore you start welding you will need to make sure you have all the tools required for the project at hand. The following list should contain everything you will need ovthe course of your welding project:

    Safety GlassesWelding MaskGlovesLeather JacketEar ProtectionPliersChipping HammerWire BrushGrinder with cutting/grinding/wire wheelsClamps

    MagnetsTape Measure/Metal RulerFume Extractorand if course, the Welder!

    Image Notes1. Welding Hood2. Leathers3. Gloves4. Angle Grinder5. Welder!6. Spring Clamp7. C-Clamp8. Fume Extractor

    Image Notes1. Angle Grinder2. Wire Brush3. Chipping Hammer4. Pliers5. magnets6. Measuring Devices

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    Step 2:Clean Your MetalAlthough FCAW is known for being a process that can get away with welding dirty metal, it is still important to clean the area of the metal you plan on welding. This isgenerally done with some sort of wire brush, grinder, or even better, a grinder with a wire wheel. Removing contaminates such as rust or paint will drastically increase quality of your welds, so taking the time to clean up your project before you start welding is always a good idea.

    Prior to taking the grinder to your work-piece, you should always take steps to make sure the metal you plan on grinding is secure. This generally done with clamps,preferably not spring clamps as they don't always exert the necessary force required to keep the metal in place while grinding on it. Personally, I l ike to use either thetable vice or a C-clamp, as they allow you to control the amount of pressure being applied to the work-piece.

    Once the metal is secure, you are free to grind away until you have removed the majority of whatever it is that is getting in the way of the bare metal that is necessary a good weld.

    *Reminder: While grinding, be sure to direct any sparks in a safe direction (i.e. not towards a person or a flammable object)

    Image Notes1. Rusty metal can be a welder's worst enemy..

    Image Notes1. Just a couple passes with the wire wheel and this section of the sheet metal wibe good as new!

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    Image Notes1. This metal is now much more weldable.

    Step 3:Cut Your MetalIn addition to welding metal that has been sufficiently cleaned, you should also make sure your metal has been cut to the appropriate length. Correctly cutting your mecan be equally if not more difficult than the actual welding, depending on what you are working with.

    An accurate cut starts with accurate an accurate scribe, or mark, on the work-piece. This is generally done with a soap stone or sharpie, and a ruler with a straight edg

    For this demonstration I've chosen to keep it fairly simple and make a 2" x 2" x 2" container out of sheet metal. Therefore, I will need 5 2" x 2" squares in order tocomplete my project. I first scribe a line 2 inches away from the edge of my sheet metal, going all the way across it. Then, I scribe a series of vertical lines going from tedge of the sheet metal to my first scribed line until I have 5 squares drawn in sharpie on my work-piece. Now I am ready to cut!

    When cutting extended lengths of sheet metal it is a good idea to use some sort of guide to ensure a straight cut. I decided to use a long piece of square bar stock to hme maintain my first, and most important cut. After that I just did my best to follow my scribe l ines and thankfully they turned out alright. For each cut you should clampthe work-piece down so that it doesn't go anywhere once you begin cutting.

    Image Notes1. Clamping square bar stock to the work-piece makes it much easier to cut in a

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    Image Notes1. Made a small mistake here, but it was nothing that another line couldn't fix!2. Each square is approx. 2 in. x 2 in.3. Using a ruler with a straight edge and 90 degree attachment is essential formaking accurate scribes.

    straight line.

    Image Notes1. Remember to be mindful of where the sparks are going while grinding!

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    Image Notes1. Here are my five 2 in. x 2 in. squares ready to get deburred (cleaning edgeswhere cutting took place). Almost ready to weld!

    Step 4:Set Up Your Work PieceOnce you have cleaned your metal and cut it to the appropriate dimensions, it is time to get your work-piece set up so that you can easily tack-weld it together withouthaving to fight with it too much. For mass production work, this is where you would typically devise some sort of jig that would allow you easily to set your pieces intoplace without having to think about it. For this project, I'm just going to use a magnet with a 90 degree angle in order to make sure my square container doesn't turn intrapezoid container.

    Making sure that the pieces you plan on welding together are secured in the exact position you plan on welding them is extremely important. Welding loose materials clead to countless mistakes and can add unwanted extra work to your project, so make sure to double and triple check your work-piece before you lay down your first tweld. After you've lined everything up accurately, it is time to start welding!

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    Image Notes1. Using this magnet helps ensure all your angles are at 90 degrees.

    Image Notes1. Make sure all your pieces line up correctly and that your edges are not uneven

    Step 5:Turn on Welder and Adjust SettingsOf course, adjusting the welder to the appropriate settings is another essential part of this project. Since the sheet metal for our container is a fairly thin gauge (approx1/16"), I will be welding on the LOW 1 setting with the wire speed set to 7. As the metal you are welding increases in thickness, you will want to increase the voltage anwire speed as you see fit. It is always good to do a couple test welds on some scrap metal to make sure your settings are right where they need to be before you actustart on your project.

    If you are unsure about what settings you should use for your own project, refer to the "suggested settings" section of the welding parameter image that has beenprovided.

    For additional tips, the last four sections of that same image give some valuable information on proper technique while welding.

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    Image Notes1. Wire Speed Control2. Power ON/OFF switch3. Low / High Heat Range Switch4. 1 2 Fine Heat Adjustment Switch

    Step 6:Tack-Weld the Work PieceAfter you've got everything lined up correctly and set your welder to the appropriate settings, tack-weld each corner of your work piece together. When tack welding, itimportant to make sure that you are actually fusing both sides of the metal together. When you pull the trigger on the torch, pay attention to where you are depositing tweld metal and that you are hitting the work-piece exactly where one piece comes in contact with another. Welding one side more than the other will lead to a lack offusion which can result in the two pieces of metal not joining together properly. Remember to clean up the area you just welded with the wire brush to remove any slaggenerated from the tack weld.

    Ideally, once you have tacked each corner together, the box will have taken shape and you will be able to see if each side is aligned and welded into the right positionnot, now is the time to fix your mistakes, as they will be much harder to correct after you finish welding!

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    Image Notes1. You should only have to hold the trigger down for a couple seconds (3 max). Ifyou weld for too long in the same place you run the risk of burning a hole throughthe metal.

    Image Notes1. After you get the first corner tacked, the rest of the squares should fall intoplace with ease. Just make sure each side lines up!

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    Image Notes1. approx 3/8" stickout

    Step 7:Fill in the remaining areas with 'Bead' WeldsAssuming that you tacked everything together correctly, you can now go back and fill in the remaining seams with bead welds. This is where you will really get to honeyour welding skills, so pay close attention to how your torch angle, travel speed, and electrical stickout affect the appearance of your welds.

    The most important thing to consider while performing these welds is maintaining consistency in the above categories. In other words, once you've figured out the prop

    torch angle, don't change it mid-weld. Your travel speed should be fairly fast, and you don't want to speed up or slow down mid weld, but maintain a constant pace.Lastly, your electrical stickout should never be more than 1/2" or less than 1/4", so keeping it at around 3/8" will be your best bet.

    Mastering the consistency of your welding technique is the key to being able to weld proficiently, and it's going to take some practice before your welds come out lookiperfect. Keep this in mind if they don't look great on your first try, just be patient remind yourself that practice makes perfect!

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    Image Notes1. While welding, remember to pay attention to how the weld metal is beingdeposited and be ready to adjust the torch accordingly.

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    Image Notes1. Assess your first bead weld, if it looks good, keep going. If not, try and figureout what you were doing wrong.

    Image Notes1. Done welding, not bad!

    Step 8:Clean up your pieceAfter you've welded everything together, there is going to be a bunch of spatter and slag left over from the flux. Now is the time to use the chipping hammer and wirebrush to remove as much of this as possible before we start grinding.

    Once you've removed as much as you can by hand, grab your pair of locking pliers and clamp it to one of the outside edges of the container. Carefully use the benchgrinder to grind down your welds until you've basically removed the outer layers of your weld and the corners are flush with the sides. While grinding, make sure you kthe work-piece safely rested on the guard. You will probably have to re-clamp your locking pliers once or twice in order to effectively grind each corner. If you welded tedges correctly, each corner should look like a seamless transition on each side and should be free of any holes or cracks. If not, you may need to go back and re-wethe areas with defects and repeat the cleaning/grinding process until you reach the desired results.

    At this point you are basically done with your container! If you still aren't satisfied with how it looks you are welcome to add your own modifications like a lid, or maybesome paint. Great job!

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    Image Notes1. Excess Slag and spatter can be removed with a chipping hammer and wirebrush.

    Image Notes1. Post wire-brushing. Looks good!

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    Image Notes1. Remember to keep the work-piece resting on the guard of the bench press tohelp you maintain control while you grind.

    Image Notes1. All done! Now what do I do with it?

    Step 9:Clean up the areaPretty self-explanatory.. Clean up the area you were working at and put all the tools back where you found them.

    Thank you!

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    Image Notes1. Don't forget to sweep!

    Step 10:Profit!Once you're comfortable welding, try to get creative and make something awesome like this robot!

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    Image Notes1. Thanks for the read, see you next time and happy welding!

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    Comments

    16 comments Add Comment

    Greg1101says: Oct 26, 2014. 11:54 AM REPThank you for this.

    Very good presentaion.

    mikeczsays: Oct 26, 2014. 11:34 AM REPBEWARE!!! Just last week they put a heart pacemaker in me. (So far, so good with the pacemaker.) But, AFTER they put i t in they tell me:

    No arc welding ! (Don't even get close!)

    Don't stand/lean over a running engine!

    Don't play with commercial or even ham radio transmitters!

    Don't stand near radar units! (Guys are putting them on pretty small boats now.)

    http://www.instructables.com/id/Basic-Guide-to-Flux-Cored-Arc-MIG-Welding/?utm_source=pdf&utm_campaign=comments#DISCUSShttp://www.instructables.com/member/mikecz/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/member/mikecz/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/id/Basic-Guide-to-Flux-Cored-Arc-MIG-Welding/?utm_source=pdf&utm_campaign=comments#DISCUSShttp://www.instructables.com/member/Greg1101/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/member/Greg1101/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/id/Basic-Guide-to-Flux-Cored-Arc-MIG-Welding/?utm_source=pdf&utm_campaign=comments#commentshttp://www.instructables.com/member/newdetroiter/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Basics-of-MIG-Welding/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Basics-of-MIG-Welding/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Basics-of-MIG-Welding/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/member/werdna17/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Great-First-MIG-Welding-Project/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Great-First-MIG-Welding-Project/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Great-First-MIG-Welding-Project/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/member/d_herbert/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Proper-Metal-Insert-Gas-MIG-Welding-Technique/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Proper-Metal-Insert-Gas-MIG-Welding-Technique/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Proper-Metal-Insert-Gas-MIG-Welding-Technique/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Proper-Metal-Insert-Gas-MIG-Welding-Technique/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Proper-Metal-Insert-Gas-MIG-Welding-Technique/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/member/bryans700/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/MIG-Welding-Common-Joints/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/MIG-Welding-Common-Joints/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/MIG-Welding-Common-Joints/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/member/noahw/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/How-to-Weld---MIG-Welding/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/How-to-Weld---MIG-Welding/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/How-to-Weld---MIG-Welding/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/member/Phil%20B/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Learning-to-Weld/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Learning-to-Weld/?utm_source=pdf&utm_campaign=relatedhttp://www.instructables.com/id/Learning-to-Weld/?utm_source=pdf&utm_campaign=related
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    Hold your cell phone in right hand (pacemaker in upper left chest).

    I guess I really needed the pacemaker, but still, I wish they would have told me all these problems with the things BEFORE they put it in me!

    emachine56says: Oct 26, 2014. 9:02 AM REPNice instructable for beginning wire welders. I think "aheibi" may be referring to E6010 (DC only) or E6011 (AC) stick electrodes. While designed for a deeppenetrating weld for tight fit-ups and for dirty conditions like corrosion, paint, dirt, oil in situations where proper prep may not be possible. I'm no pro but Ihave used both with similar results. Many consumers have an AC or AC/DC box like the Lincoln AC125 or AC 225/125 both will cut with the E601* stickswhen duty cycles are observed. I know of 2 electrodes available overseas, the HILCO Cutil 4KG both designed specifically for this task...I'm sure there aremany more. Great job though, keep it up!

    SparkySolarsays: Oct 24, 2014. 7:38 PM REPThank you for your nice instructable.

    Rima

    aheibisays: Oct 23, 2014. 1:51 PM REPWow, this awesome for begginers.

    Why didn't you used cutting electrodes instead of the grinder?

    SLOMakerSpacesays: Oct 24, 2014. 11:27 AM REPWhat do you mean by "cutting electrodes"? If you are talking about carbon arc gouging, we are presently not capable of that at this shop. Also wanted use something that was easily accessible.

    aheibisays: Oct 24, 2014. 12:38 PM REPNot torch(plasma) cutting. The electrodes can cut/melt metal. My freind use them to disassembly buildings, instead of using the torch cutter - the gas isvery expensive in my country.My freind using Zika's electrodes(http://www.zika-welding.com/product/z-72/). But I guess you can find more companies in the US.

    SLOMakerSpacesays: Oct 24, 2014. 1:46 PM REPOh alright. Here in the states I believe we call this type of cutting "carbon arc gouging". It is great for cutting very thick or hard to reach areas,however the cut is usually very dirty and uneven, therefor it is inappropriate for this application. It would be nice to have access to one here at oshop, though.

    kakashibatosisays: Oct 24, 2014. 1:44 PM REPI thought it was humorous that all of the welding turned into a cheerful robot at the end. I was expecting it to be just a metal box. Nice job.

    Phil Bsays: Oct 23, 2014. 10:18 AM REPI appreciate this. A number of people I know would benefit from having and using a welder, but hold back for various reasons.

    Some of the pictures have not loaded. If your picture files were a megabyte or so, could you repost them at 100 to 200 killabytes?

    MIG means metal inert gas and implies a shielding gas covers the weld until it cools. Flux core has a chemical composition powder in the center of thewelding wire, and it cover the weld to protect it from exposure to air before it cools. Technically, your welder is not a MIG welder, but a Flux core welder.

    SLOMakerSpacesays: Oct 24, 2014. 11:28 AM REPFixed the title in response to this comment. Thank you!

    seamstersays: Oct 23, 2014. 11:04 AM REP

    The photos should be loading correctly now. (It was an problem on the site.)

    PurplePeoplesays: Oct 23, 2014. 12:10 PM REPPhil B is right... unless your setup has a pressurized tank with a shield gas (such as argon or a mixture of argon/CO2), you really should remove theterm "MIG" from your tutorial.

    Phil Bsays: Oct 23, 2014. 12:05 PM REPThanks.

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  • 8/10/2019 Basic Guide to Flux Cored Arc MIG Welding

    19/19

    donttrustthepigsays: Oct 23, 2014. 2:54 PM REPIf you want really clean welds, wipe the metal down with a degreaser before welding.

    seamstersays: Oct 23, 2014. 9:26 AM REPThis is an excellent tutorial on welding. Thank you.

    http://www.instructables.com/id/Basic-Guide-to-Flux-Cored-Arc-MIG-Welding/?utm_source=pdf&utm_campaign=comments#DISCUSShttp://www.instructables.com/member/seamster/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/member/seamster/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/id/Basic-Guide-to-Flux-Cored-Arc-MIG-Welding/?utm_source=pdf&utm_campaign=comments#DISCUSShttp://www.instructables.com/member/donttrustthepig/?utm_source=pdf&utm_campaign=commentshttp://www.instructables.com/member/donttrustthepig/?utm_source=pdf&utm_campaign=comments