Re: STICK WELDING on thin sheet metal

I sometimes shake my head when you break down the sheets and weld them back together Rosy. Mas madali yata wag na lang putilin :blink:. Hehehehe, its a joke ha. can't really comment much yet since I have no weld time yet in my hands. But soon I will join you cutting and putting them back together for practice (it is what makes one proficient at what he/she does). Kaya for now, hindi ko muna puputin ang metals :agree:.... kahit ingit na ingit na ko:sigh: :peace:

Re: STICK WELDING on thin sheet metal

Again to continue with the welding practice/exercises : :cheerleader3:

Now these are the two additional items/configurations that I will also be working on.

In these two images, I started to tack weld the plates.

Re: STICK WELDING on thin sheet metal

And more tack welding of the plates for the PIPs ;

These are the images of the second plate.

And these are the images of the third and fourth plates to be welded.

Re: STICK WELDING on thin sheet metal

SO all in all these are what I will be working on for this exercise/practice : :rolleyes:

I WILL CONTINUE IN A FEW DAYS, practice welding again resumes. 😀

Re: STICK WELDING on thin sheet metal

I sometimes shake my head when you break down the sheets and weld them back together Rosy. Mas madali yata wag na lang putilin :blink:. Hehehehe, its a joke ha. can't really comment much yet since I have no weld time yet in my hands. But soon I will join you cutting and putting them back together for practice (it is what makes one proficient at what he/she does). Kaya for now, hindi ko muna puputin ang metals :agree:.... kahit ingit na ingit na ko:sigh: :peace:

HA HA HA HA HA , LOL LOL LOL , Yes it could have been easier, or much easier if I didn't cut or sliced up the thin sheets any more but there were reasons for me in doing so, and if I didn't then the challenge that I gave myself in doing this stick welding on thin sheet metal will not be complete coz its part of the whole process. I have to think of different scenarios that I might encounter in welding metals. Welding thicker metals are a no problem for me, they are much easier to deal with, you will not think so much of burn throughs or metal warping nor the changing so much of ampere settings and welding rods to use.

But with thin sheet metals I have to challenge myself, I have to study and try to learn coz welding on this kind of metal is very tricky, hard, frustrating and very unforgiving specially when using only a stick welder. Not many welders do this kind of welding, they'd rather use oxy-acetylene for thinner sheets of metal.

Another reason why I do cut up the sheets is to have more chance to perform the exercise/practice on putting them back again by carefully welding and not as much as possible burning a hole or two. One or two exercises is not enough, I have to do it again and again to be able to control my hand, wrist and the whole arm in applying the weld lightly but with full penetration on the sheet metal.

Timbs, I have been on this for more than a month now and going on the second and I'm happy to say that the challenge I gave myself has bear fruits or good results, have discovered new techniques in weld applications, more hand control, can easily rebuild burn holes and developed such confidence in applying weld on thin sheets. Learned also the proper use of different types of welding rods and the proper use of ampere settings on different thickness of metals in which before I didn't care much really.

You and Jay have very good welders and I urge you to in a way do the same challenge on
yourselves if time permits, sayang yung galing ng MILLER at ASEA welders. LOL

Sorry for a long reply, I simply want to share my thoughts., CHEERS !!

Re: STICK WELDING on thin sheet metal

It is such a good thing that we have now computers and we have video clips and YouTube to watch. To those guys very much interested in welding and in learning on how to use and apply good welds, watch welding videos on YouTube, read and follow instructions well. This is good too for those who cannot go to a formal training school for welding. 🙁

I highly recommend watching or subscribing to all videos of Weldigtipsandtricks.com . Very clear narration and explanations on how to apply welds properly whether for stick, tig or mig welding, that's what I do now, watch their videos and practice what I have assimilated since I don't have yet the luxury and time to attend a TESDA welding seminar or training. 😀 :p 😉

Re: STICK WELDING on thin sheet metal

And to update my welding exercises/practice, here are the new 1.60mm plates that I have prepared for welding. Still some weld applications were bad, some fairly good and some can also be considered really good, but that's how it is, I try my best to correct and find the proper way to apply a good weld puddle on the tee joints specially on this thin sheet metal.

Some punched holes will appear, but that is normal since applying a 6013 1/8welding rod directly on the metal with a medium setting will really be to much for the sheet metal so still proper preparation is still very much required.

Again pardon me for utilizing some full size in some pics for the purpose of easily viewing the good welds and the bad welds 😮 and while going through the picks slowly and stopping, try to study each weld applications.

Ok I'll start with this set up and here is a top view of the subject. Then I will be rotating the subject clockwise so that all angles and welds can be seen.

In this angle, the weld puddle looks fairly good but when reaching the corner to turn, well I made some burn throughs or holes due to reduced my speed in turning. By the way all joints in the PIPs were first prepared by making two passes of 3/32 welding rod with a setting of low or spot only after which it was lightly sanded or grinded and then capped it with a standard 6013 1/8 Wipweld welding rod under a setting of medium or maybe that is an 80 or 95 amps.

In this side and angle, you can see the burn hole on the left and on the right side farther you can see the ugly and bad weld application. Sometimes I just don't know why the welds still make some craters on not completing the full weld application.

Re: STICK WELDING on thin sheet metal

Still a continuation of the PIP.

From this angle and side you can see the difference of the front and rear weld puddles. Sometimes it really puzzles me how come these welds are coming out like this when the welding rods are already the right ones, correct already in speed travel, the distance between the rod and the surface to be welded and prorer settings have been followed and of course great hand control is in there already. :confused:

Here is another side showing the ugly weld on the joints.

On this first subject, I could have grinded all of the weld puddles and re apply some more welds until I get a good one and be able to present immediately good weld application but rather not coz I wanted to see and compare if there will be improvements on the second subject to be welded. :rolleyes:

Re: STICK WELDING on thin sheet metal

AGAIN TO CONTINUE WITH THE PIP :
And this is the second subject to be welded.

Here in this image, I think some improvements are already evident in the weld applications.

In these two images above, good weld puddles have been achieved. Just have to persevere and just keep on trying. Complete hand control, uniform speed travel and distance of rod to the metal. 😀

Re: STICK WELDING on thin sheet metal

AND AGAIN TO CONTINUE THE PIP. :agree:

Yes, definitely some great improvement on the weld application though with some burned holes on the upper portion.

And then in this image I flipped the sheet plate to see the underside and also see the total fusion or penetration of the weld. But of course there will definitely be penetration since this is only a thin sheet metal. LOL :p

Re: STICK WELDING on thin sheet metal

OK, have to continue posting later the third subject to be welded., have to do some errands first.

Re: STICK WELDING on thin sheet metal

TO CONTINUE WITH THE WELDING PIP :
And this is the third subject to be welded.

If this sheet looks familiar to you, well its the old plates where I did practice putting bead welds, bend the plate in the middle and its base is another old practice plate joined together, and there it is , still has become useful object for practice.

There's the right side welded, burned some holes and still created two craters. I applied here the inverted smiley manipulation, then stopped in the middle coz I run out of welding rod then started again going to the middle end but then created again two craters.

And here is the left side of the plate. Did quite much better here, no holes or craters made.On this weld pass I applied the push and pull technique, very controlled weld application with lesser movement or manipulation.

Here I reversed the plate welded to show the full penetration of the weld, its like the welds were popping out from behind too.

Re: STICK WELDING on thin sheet metal

On the second and third practice subjects I applied first two stringer weld pass using the 3/32 welding rods for lower amperes to prepare the thin surface sheet, sanded or grinded the welds with an angle or die grinder after which I made a hot pass or capping using a 6013 Wipweld 1/8 welding rod used for higher amperage. Now if the application of welds didn't turn out quite satisfying, I would do some grinding again then do another weld pass, and if it give again an ugly or terrible weld, then another session of grinding follows and then make another weld application.

These two grinders have become very useful too in cleaning up some unwanted welds. :p

And then these two will be what I will be practicing on for now or I might add another object so that I can do more practice/exercise.

So I guess I'LL be posting these two in a few days and thanks for viewing this PIP. :thanks:

Re: STICK WELDING on thin sheet metal

Wow nice project sir Robert and the picture was very clear!!
A signature shots of a GE DIGITAL CAMERA Model = J1455.. superb cam!!
More power and will wait for more post from the expert!!

Re: STICK WELDING on thin sheet metal

HA HA HA HA HA , Thanks pyth but how did you know that I'm using a GE J1455 Digi Cam ?

Wild guess siguro ano ? Any way I would sometimes use also my son's GE X500 Digi Cam :p and speaking of quality and performace !!! Hands down ako, they are really superb point and shoot digi cams, I just love them and it was worth purchasing the two models. 😀 :jump:

Thanks again pyth, :thanks: . NYHEKS !!!!! Sinong expert ? LOL