question for welders

[Dragsinger]

The setup;

it is any day of the week. I ready the MIG welder setup and begin to weld. The work goes beautifully, welder setup sounds perfect, weld is laying and penetrating like text book. I can easily see the process and moves along just as expected.

Later I pickup the TIG torch and even though my TIG experience is limited it also goes nicely. Bead looks good, heat signature looks just right.

The MIG machine is a Miller 185 about 15 years old but in excellent condition. I run .030 wire with 75/25 argon co2 mix.

The TIG is a new Miller Dynasty 200 DX with straight argon.

Now, fast forward two days, the machines are set exactly the same, nothing about the machines or setup has been touched.

And I am welding very poorly, MIG is sputtering, burning through, bead stacking up too high, whew, awful sounding and looking. Same with the TIG, looks awful, Tungsten balling up, burning through, etc.

So, my question; it is reasonable to assume the only thing changed is the operator [me] Why does this happen? Do some of you have such an experience?

I have learned that when this happens just forget about welding for the day and do something else. After a few days I can try again and all will work fine.

If I earned my living as a welder I would starve! My welding is personal race car work only.

Any ideas to improve my bad days?

[Alan Roehrich]

Yeah. There's a book sold by most book stores that have an automotive section, it's from HP Books, the author is Richard Finch, I think the current edition is called "High Performance Welding". Buy it, read it, follow it. I don't think I've run up against a welding problem that the book does not provide a solution for.

[Robert Swartz]

Clean metal, good tips, proper torch distance, the right settings. I've had the same problem. One day you get good clean welds, next day they look like dog $h*! If the piece you are working with has any dirt, grease or serious imperfections, that can give you a bad weld. Make sure the gas is set properly. I have a story on that!

I'm between you and Alan, will be 60 next month. My eyesight sucks. My hand/eye co-ordination isn't what it once was. It wasn't very good to begin with. I bought a new Miller welder a few years back because, it's hard to find anyone that will do small jobs around here anymore. Also, when you live out in the country, if you need to do something on Saturday nite or Sunday, you're on your own.

[Dragsinger]

update report,

Thanks for all the tips, I appreciate the ideas. In addition to better cleaning the biggest improvement was gas pressure. I had the pressure too high and then tried raising it even more.

Finally I realized the excessive gas flow was moving the flame kernel. It was worse in a corner were the gas had no place to escape. The Tungsten "flame" was moving around unpredictably.

As I lowered the gas flow, the weld control improved. I will continue to back off the gas pressure to find a sweet stop. Just finished a good looking weld at 20 pounds showing on the gauge.

With the MIG a clean tip and clean nozzle made a big improvement. The tip had melted to the point of causing the wire to feed slower than normal.

Simple fixes but sometimes a fellow can't see the weld for the slag [or something like that]

[James L Miller]

I took a welding class at a local community college just for grins. I hadn't done a lot of welding in a long time. I got to play with their Miller TIG welders. I liked the Synchrowave 250DX ones the best. I had pretty good luck with the new inverter welders. They seemed to weld nice, but sure were noisy compared to the DX. Anyways, I was grinding the tungsten by rolling it in my fingers against the wheel (horizontal). They said that can cause the arc to be unstable. They said to grind towards the tip (vertical) to make the lines of grinding along the centerline of the tungsten. I think they also said the 2% thoriated was out, now they have some other elements to make the start easier without the health issues. I think the pure tungsten had some problems too. This website was recommended by the instructor.

http://www.weldingtipsandtricks.com/

[Patric Fox]

You could also try a flowmeter instead of pressure for your shilding gas.

[Alan Roehrich]

Originally Posted by Dragsinger

update report,

Thanks for all the tips, I appreciate the ideas. In addition to better cleaning the biggest improvement was gas pressure. I had the pressure too high and then tried raising it even more.

Finally I realized the excessive gas flow was moving the flame kernel. It was worse in a corner were the gas had no place to escape. The Tungsten "flame" was moving around unpredictably.

As I lowered the gas flow, the weld control improved. I will continue to back off the gas pressure to find a sweet stop. Just finished a good looking weld at 20 pounds showing on the gauge.

With the MIG a clean tip and clean nozzle made a big improvement. The tip had melted to the point of causing the wire to feed slower than normal.

Simple fixes but sometimes a fellow can't see the weld for the slag [or something like that]

For both MIG and TIG, use a flow meter, as Mr. Fox suggested. The flow meter works at a given pressure from the regulator, and flows based on a valve.

Keeping everything clean is very important.

I usually use nozzle guard on the MIG nozzle. You need to make sure it is the correct size and shape, and that it fits correctly. Also make sure you keep the gas ports in the gun clean.

I use uncoated ER80S6, or if that is hard to find, ER70S6 MIG wire. The copper coating on any welding wire or filler rod contaminates the weld. Even copper flash.

As Mr. Miller suggested, grind the tungsten to a sharp point, and grind it parallel to the length of the tungsten. Wear a mask when you grind tungsten, even if it is not thoriated.

[Dragsinger]

if you have had a day at the track when you could do no wrong and everything just feel in place, then the next outing at the same track in the same unchanged car you make every mistake possible, them you understand about my welding issue.

I has been suggested a draft may be upsetting the shielding gas, I will be more sensitive to that possibility.

Bottom line, I "think" some days I simply am not in the proper mind set. However, I understand a full time welder could not allow such wavering of ability. This is my confusion.

It may simply be lack of experience not being able to recognize the problem and compensate for it.

[Alan Roehrich]

Health and age can be a problem, not sure how it applies to you.

I know at 51, some days I feel and see better than others. I don't see real changes in my performance at work, other than needing my reading glasses more. But I can see where I could.

If you have high blood pressure, diabetes, or other problems, it can make a big difference. So can your over all mental and physical state.

Welding requires fine motor skills, excellent hand to eye coordination, and clear thinking. Anything that has even a small effect on any of those can have a big effect on welding.

[Dragsinger]

Alan, you may be very close to the root cause. I am 67 and overweight. In addition, my eyesight is a challenge. I have a set of special "up close" glasses I use when welding.

Not being able to clearly see the work may be my biggest issue. I will experiment with better lighting.