by Bob Moffatt

Welcome to Got to question for you true fabricators out there. How many of you, when you're runnin' flux core wire, you get ready to do multiple joint configurations and positions and directions of travel, do you go back and adjust your machine?

Personally, when I'm runnin' horizontal and flat, I crank it up pretty high, run hot. I turn it down if I'm gettin' ready to do an uphill run on somethin'. Bein' in a groove or fillet weld. And then how 'about thin material? This is 11 gauge, I did a mock-up run.

-I'm playin' around with this wire over here. And I ran it down pretty low. I think I could run it even lower yet, but this is 11 gauge material. It's right around an eight of an inch, and I threw an 045 flux core fillet weld in it. Again, I'm thinkin' here, I'm lookin' at some drawings. And I was thinkin' about just, you know, not changin' settings, and kind of fly through this stuff with some speed and quality. Keep the right size, keep the spatter down and everything. So, I want to experiment with this wire, just run. I want to go down low on this 11 gauge. And then I want to mock-up this run where I do a horizontal fillet, just lap, come up into here, run part of this. Not change settings, and just go from horizontal and go uphill and see what happens. See if we can keep the same acceptable size of weld and rock on, we'll see what happens. Good experiment for me. Hope you enjoy it.

-Okay, I ran this first weld. I forgot to glance over at the machine and read the ampers. But I'm thinkin' it was down around 200. I don't think it was much higher than that. But I ran it at 20.5 volts. 300 inches a minute on wire-feed speed. I am running off of a Esab 285. And I'm runnin' off the flux core setting on this machine. 045 wire on 11 gauge, that's the important part. I really kind of like the first part of this. It's a little smaller, apparently I slowed down.

-My bead got progressively wider by a little bit. I have a couple of specks of spatter, not bad. But I really like the start of this bead. I like the profile of it. That ran pretty smooth and pretty quick. I think, and you know, again, this is the first time for me to run this. I'm kind of playin' around with it and learnin' myself. So, so far, I'm seein' that it runs down on the low end. How far low, I don't know yet. I could mock up some more of these pieces. So now, I want to go into some 5/16 plate and do a horizontal fillet, couple of 'em actually. And then I want to do this t-joint, not change settings, but just take off and do the horizontal fillet part, and just go uphill with it and see what happens without changing settings. I do believe I want to run about 25.5 volts. And I want to run about 425, 430 inches a minute on the wire-feed speed there.

-Camera guy wants me to talk while I chip my slag. I kind of butchered this part of the lap weld over here. I don't like the toe of my weld. I do like my fillet. I'm really interested in what this fillet looks like because, while I was standin' over the top of this thing, it was like diggin' down in here. I need to get some light on this guy here. Pretty nice profile of fillet weld in there. I did the same thing over here. Pretty much the same settings. Hey, here's a cool little product for you. Pferd, they put out this bristle brush here where all the bristles are right down into a point. I think that's a really cool, smart idea.

-I'm going to get under the toe of my weld under here, on the horizontal part that I did for the fillet. I'm a little peaked in here, on my vertical up. But I didn't change settings. And I definitely think that I could do a little better by actually going up in a half of a volt, leave the wire where it's at. 435, we're above 200 somethin' amps. Probably around 225 or so. 25.5, I think 26 might be the ticket. Anyway, we've got a mock-up run over here that I kind of set the machine with. I actually thought I could get away with it. I like this profile here, it's very acceptable. I may have bumped that wire-feed speed up too high on this side.