by Jason Becker
In a previous video we discussed Flux Cored Arc Welding in the 2G position. We are now rotating the plate 90° and going vertical. The joint configuration is similar to the horizontal plate except we now have both plates beveled at a 22.5° angle for a total of 45° included angle.
We have also started to include welding symbol interpretation into the videos everywhere we can. We tried it in the last video and the feedback we received was very positive. We set the plates up at a 1/4"-5/16" root opening and ran the root at 160 ipm for our wire feed speed (WFS) and 19.5V on the ESAB Rebel 285 using Select Arc 701 .045 Flux Cored Wire. It is a self-shielding electrode so you guessed it straight polarity.
We started to run the root and about 2 inches in I realized i did not set the adequate tension on the drive rolls and experienced some feeding issues due to my complacency. But all is not lost. We used this mistake to take a moment to show the audience how to repair the mistake we created. I was able to show a great product from Weiler abrasives that is made to grind on the outside edge of the wheel. Not all grinding disks are capable of doing this. Injury could result if you try to use a disk in this manner that is not designed to be used that way. Once we showed the fix and re-tensioned the drive rolls, we were ready to run the root again and it went great. The root tied in very smooth and flat, and created a great foundation for the next passes to follow. We went right in to the fill passes cleaning the plate in between each pass and ensuring all the slag was completely removed.
After the 4 fill passes we were ready for the cap. We went with a 3 bead cap and it turned out exactly as planned. all three passes were about 1/16" above the plate which is right within the AWS weld reinforcement limits. I was very happy with how smooth the welds ran and the ease of use. Select Arc makes some great flux cored wire. The main thing to watch when you are running flux core is the Contact Tip To Work Distance. If you get too close you will most likely develop porosity in your weld. Too far and you will experience some push back and cold spots in the puddle. Both situations are less than desirable, especially on a test piece. Hope that helps out anyone looking for this information, until next time, Make Every Weld Better Than Your Last.