Welding FAQ

RJohnson · Jul 16, 2002

Rockyroad
Sure am sorry to hear about the dry spell your having. It is just the opposite here in Texas. Flooding down San Antonio way and flash flood warning in effect for today. It has already rained today and it looks like another wave is on it way. It sure has been a crazy year, we haven't seen a day over 100 yet (thank God) and I usually let the place at the lake go and quit mowing because the heat burns it up. But not this year, can't keep up with it.
As for welding the E6011 is a good rod for giving you deep penetration on thicker metal but I tend to like E6013 because the bead is smoother and the penetration is not so great. Alot of people call it a junk yard rod but it is okay as long as you stay with what it was designed to do. Around tractors you will find some low alloy steels and the E60xx rods are just not strong enough. Then many people go the a E7018 rod but this is a low-hydrogen rod and will require that it be keep in a dry environment. My father-in-law keeps his on top of his water heater/w3tcompact/icons/smile.gif. Keep those rods burning and I will try to send you some rain.

Randy

EdKing · Jul 17, 2002

Well, I have to say, I like my new weldor. I have been going out for about an hour to an hour and a half each evening (time permiting) and welding more stuff on to my "sculpture". The sculpture will eventually find its way to the trash, but it sure helps me in learning the weldor. I did the same thing when I first got my MIG weldor, and one thing for sure, the learning curve for a stick weldor is definitly steeper. I am starting to get to the point where the welds are looking almost passible. Sure is lots of fun.

Hugh · Jul 18, 2002

I have a 225 amp AC buzz box that I have had for over 20 years and love it, the only thing I would done different was get a AC/DC welder as you can use different rods and get better welds. Finaly decided to upgrade to a MIG (and keep my buzz box).

After going to the local welding supply company and surfing the net I found www.cyberweld.com and a Millermatic 175 with a cart for $675.00 (FREE SHIPING). I then went back to the local company to see if they could get close to the price. They told me they could not get close to the price and suggested I order it (WOW).
I told them I was concerned about support if I ordered from an out of town company. They told me they were a Miller repair shop, had no hard feelings and would welcome my business.
A friend of mine decided to also order the same welder, by ordering two welders Cyberweld could then have them shiped directly from Miller and gave us a $25.00 discount on both welders (12.50 each). We just received the two welders and went to the local co and got two 11 lb reals of wire, they told us what a great welder and deal we got and thanked us for the wire business (WOW).
Also on tanks the local welding co would give us a 5 year lease, for the same price we found a life time lease from the local scrap yard guy. We also ordered Hobart auto darkening hoods and saved big bucks.
Every one is happy and we saved three or four hundred bucks.

RJohnson · Jul 18, 2002

Ed
One thing that I would caution you to be careful about and that is the duty cycle on your buzz box. (And it applies to all welding machines) One of the thing about the less expensive units is that they have a reduced duty cycle. 40% is common and I have seen some as low as 20%. What this means is that if you have a 40% duty cycle you can weld 4 minutes out of every 10 minutes. Then you need to let the machine "rest". So as you are practing make sure you do not exceed the duty cycle as you can damage your welding machine and affect the quality of the welds being produced.
You know the older I get the smaller my duty cycle gets/w3tcompact/icons/smile.gif but the wife won't belive me when I tell her my duty cycle is 10% /w3tcompact/icons/grin.gif.

Randy

Bird · Jul 18, 2002

<font color=blue>duty cycle . . . seen some as low as 20%</font color=blue>

I have a little "Miller de Mexico" Comparc 80 that's 10%./w3tcompact/icons/laugh.gif You don't want to tackle any big jobs or get in any hurry./w3tcompact/icons/wink.gif

MDNick · Jul 18, 2002

My new AC22/DC125 Linc. does have only a 20% duty cycle. On a stick machine this does not seem as hideous as on a mig or tig machine. By the time the novice welder studies his welds, puts in a new electrode, scratches his head, hits his project with a hammer, drinks a beer, the duty cycle is fairly well covered. However, the 75 amp setting has a continuos use for 1 hr duty cycle. For most of my work 75 is to small, but I thought that was odd. It goes significantly lower that 75, so not sure whether it is a transformer tap issue or what, It is only for 75 amp AC, the same position of the dial for DC is 55 amp, but there is no mention of an increased to 1 hr duty cycle for DC. I study what I am doing enough that I don't think 2 minutes of making sparks and 8 mins of chillin' out is a major limiting factor. I hope.

Nick

Bird · Jul 18, 2002

<font color=blue>By the time the novice welder studies his welds, puts in a new electrode, scratches his head, hits his project with a hammer, drinks a beer, the duty cycle is fairly well covered</font color=blue>

Nick, I never realized you knew me so well./w3tcompact/icons/wink.gif

crb478 · Jul 18, 2002

While you certainly need to stay with in the duty cycle it is often not as bad as you would think. I saw a study of welders at a ship yard using wire welders and they only averaged 85% when welding plates together with everything in place to make the welds as efficient as possible. By the time you line everything up change rods knock off slag ect. it will eat into the duty cycle time.

MDNick · Jul 18, 2002

Bird,

I know a lot of people real well. It would appear. Start anything with novice and include beer, and you got a whole bunch of people covered. /w3tcompact/icons/laugh.gif

EdKing · Jul 18, 2002

Randy
Thanks for the tip, I checked the duty cycle on the welder, as I wasn't sure if it was like my MIG, which will not let you exceed the duty cycle. It shuts down until it is cool enough to weld again. The stick welder I got, has a duty cycle of 20% at max output of 225 amps, but 100% at 100 amps or less. I haven't had the weldor turned up past 120 amps for a short period, I am finding with the metal I am working on 90 to 100 amps is working fine. My brother has an older Miller ac/dc unit with 100% duty cycle that I can use if I ever need to weld something that heavy and large.