Splicing a small I beam together

[ericher69]

"Just followed card settings on the front of 252." Man, this is really strange - you got me curious so I went looking - the cards on the front of MY 252 (about a 5 yr old machine) don't show ANY voltage settings above 25.5, so I got even MORE confused - checked the miller online calculator Miller - MIG Welding Calculator And it doesn't even HAVE settings for 1/2", except for spray transfer with .045 wire. Then I checked the mm252 .pdf I downloaded last year, and found your settings - 1/2" steel, .035 wire, 29.5 volts @515 IPM with C25 gas. Your machine is newer than mine, so somehow those numbers must have been changed AFTER mine was built. I'll see if I can find the paper manual that came with mine and compare those #'s, but I can sure see why your welds were kinda hot The 3/8" settings in the newer manual are quite a bit higher voltage as well, compared to the online calculator and my older machine's cards, but 1/4" settings are nearly identical for old and new. Personally, I think you might do better ordering one of the "slide rule" mig calculators, they're about $5 - I keep one with my machine 'cause the front cover is a PITA to open and close, and because I don't wanna go online every time I change settings. At the voltage settings they call for now, I don't see how you'd keep from going into globular transfer... Steve

Thanks for the calculator!

Yup it was definitely rock in' at that Voltage setting and ipm setting.

Give it a go when you have a chance.

From what I understand with globular I would have increased spatter and decreased penetration. If I would have moved any slower pretty sure I would have burned through!

I did get some porosity on the top plate that I needed to grind out. I think what happened maybe the reg iced up a little and by taking a break to grind allowed to thaw.

Reg was very cold. Was flowing 25CFHy

Good informative thread! The type I had almost given up on looking for here Looks like the welding forum just might get back on the track Thanks for posting your project.

Your welcome lets all learn what NOT to do lol

Sent from my iPhone 5s 64Gb using TractorByNet

 

[Sodo]

Your welcome lets all learn what NOT to do lol

Yup what "NOT to do", is quit every time someone on the internet says "you can't do that".

I was amazed with what SA did with my 211. He maxxed out the heat and successfully welded 3/4in plate!

In real life, the pros git-er done! But don't try this at home

 

[BukitCase]

Got a chance to check my older, paper mm252 manual - using C25 and .035 wire, here are their recommendations

1/2" = 23.5/475 3/8" = 21.5/425 1/4" = 19.0/320 3/16" = 18.0/280 1/8" = 17.0/245 14 ga. = 16.5/200

Seems like the thinner settings are nearly identical old vs new.

Even the Miller slide rule MIG calculator is slightly different than their online version.

Sure makes a case for the "pick a setting and tune it by ear" method... Steve

 

[ericher69]

Got a chance to check my older, paper mm252 manual - using C25 and .035 wire, here are their recommendations 1/2" = 23.5/475 3/8" = 21.5/425 1/4" = 19.0/320 3/16" = 18.0/280 1/8" = 17.0/245 14 ga. = 16.5/200 Seems like the thinner settings are nearly identical old vs new. Even the Miller slide rule MIG calculator is slightly different than their online version. Sure makes a case for the "pick a setting and tune it by ear" method... Steve

Here is a reply tweet from MillerWelders when I asked about 0.035 wire 25/75 mix 1/2" steel.

Told them 29.5V and 515ipm this is what they said;

https://twitter.com/millerwelders/status/512337559704588288

Sent from my iPhone 5s 64Gb using TractorByNet

 

[BukitCase]

Man, that was kinda succinct

Sorta makes me wonder if there's anybody left at Miller that's old enough to know how much it changed since 2007 (the date on my manual)

Or maybe it's just the typical corporate stock-holder driven crap of "cut jobs til it quits working, then put one back"

Personally, I'm gonna start keeping a notebook and make my OWN "this is what works" chart... (shouldn't be too hard, since the Miller slide rule Mig calc hasn't been far enough off to worry about yet)

 

[BukitCase]

Just noticed Miller doesn't charge shipping on their slide rule types, you can get all three for $4. I bought mine thru Cyberweld, prob'ly paid too much

https://www.millerwelds.com/resources/tools/#calculators

 

[dragoneggs]

Man, that was kinda succinct

Sorta makes me wonder if there's anybody left at Miller that's old enough to know how much it changed since 2007 (the date on my manual)

Or maybe it's just the typical corporate stock-holder driven crap of "cut jobs til it quits working, then put one back"

Personally, I'm gonna start keeping a notebook and make my OWN "this is what works" chart... (shouldn't be too hard, since the Miller slide rule Mig calc hasn't been far enough off to worry about yet)

Yeah the personal notebook for your settings based on tweaking the prescribed settings is a great idea... I started the same.

 

[ericher69]

Man, that was kinda succinct Sorta makes me wonder if there's anybody left at Miller that's old enough to know how much it changed since 2007 (the date on my manual) Or maybe it's just the typical corporate stock-holder driven crap of "cut jobs til it quits working, then put one back" Personally, I'm gonna start keeping a notebook and make my OWN "this is what works" chart... (shouldn't be too hard, since the Miller slide rule Mig calc hasn't been far enough off to worry about yet)

I'll use your 2007 settings and send it to them to ask for an explanation on differences

Sent from my iPhone 5s 64Gb using TractorByNet

 

[ericher69]

Just noticed Miller doesn't charge shipping on their slide rule types, you can get all three for $4. I bought mine thru Cyberweld, prob'ly paid too much https://www.millerwelds.com/resources/tools/#calculators

BukitCase;

Here is the replies from Miller.

https://twitter.com/millerwelders/status/512690766842306562

and
https://twitter.com/millerwelders/status/512690630213246976

Send them your info via email and they will send you new cards!

Sent from my iPhone 5s 64Gb using TractorByNet

 

[Big Barn]

BukitCase; Here is the replies from Miller. https://twitter.com/millerwelders/status/512690766842306562 and https://twitter.com/millerwelders/status/512690630213246976 Send them your info via email and they will send you new cards! Sent from my iPhone 5s 64Gb using TractorByNet[/


Thanks for clarifying that info,Eric. I love that Miller's "continued performance evaluation". I'm going to have to remember that phrase. Terry

 

[BukitCase]

Sorry, but if 6 volts is a "slight change", then why do they bother with TENTHS of a volt changes on their machines??!?

Oh, and did they ask you if you'd like fries with that?

 

[ericher69]

Sorry, but if 6 volts is a "slight change", then why do they bother with TENTHS of a volt changes on their machines??!? Oh, and did they ask you if you'd like fries with that?

Well maybe they realized the error of their ways and revised things!

Maybe your built in the USA MM252 was/is a much more capable machine then my assembled in the USA mm252...

Sent from my iPhone 5s 64Gb using TractorByNet

 

[ericher69]

A little primer and paint goes a long way!

Sent from my iPhone 5s 64Gb using TractorByNet

 

[Underdog57]

Looks very good! Nice job.

 

[ericher69]

Looks very good! Nice job.

Thanks Hi Vis yellow.

Steel brushed with 4-1/2" angle grinder

Blew off dust with compressed gas

Primed

2 coats paint

Voilà

Sent from my iPhone 5s 64Gb using TractorByNet

 

[firemanmike69]

Thanks Hi Vis yellow. Steel brushed with 4-1/2" angle grinder Blew off dust with compressed gas Primed 2 coats paint Voilà Sent from my iPhone 5s 64Gb using TractorByNet

Looks great, Now stencil "s.w.l 500lbs" on it and it will look just like a store bought one.

 

[ericher69]

Looks great, Now stencil "s.w.l 500lbs" on it and it will look just like a store bought one.

Good suggestion!

Or 2000lbs if I would care to proof it.

Sent from my iPhone 5s 64Gb using TractorByNet

 

[dragoneggs]

Nice yob! You got me thinking on yet another proyect, eh? :thumbsup:

 

[Sodo]

Or 2000lbs if I would care to proof it.

Someone can tell you what the max load (or max deflection) should be just don't go beyond that.
What could be more fun than proofing it?

 

[jwmorris]

This is the 10" beam I welded together. It spans 30' and sagged 1/16" in the center with a 1500 lb load.

Plates on both sides and tabs lag bolted into the rafters to locate it side to side.