Updated: Apr 5
If you've been in the welding industry for any period of time it's safe to say you've probably taken a bend test. We've done our fair share of face and root bends on this channel, but today we're showing side bends on a 1" plate test in the overhead position.
Today's test qualifies for both D1.1 and D1.5 codes. Before we get into the welding technique and things to look out for, let's talk about material prep.
You should always make sure you have good material prep before welding, but it's especially important on test day. Improper material prep can be the difference between passing and failing.
Remove Mill scale
Always remove mill scale prior to welding when possible. Today we're using a Weiler Tiger 1/4" AO grinding wheel.
Bevel Angle and Root Opening
The bevel angle on our plates is a 45 degree included angle. That means each plate is beveled at 22.5 degrees. The root opening is 1/4" with no land.
Run on and Run Off Tabs
The run on and run off tabs are a little different than we normally have on these one inch plates. We created a side wall to extend the plate bevel. The side walls keep the weld nice and uniform all the way through to the end.
When we lay in the root we run a very slight weave. The reason we do this is because we're running a 1/8" rod and have a 1/4" gap. Our weld bead can be up to 3 times the size of our rod, so we are safe to do one pass here.
The second pass will be the only pass other than the root that is a single pass. After the first fill pass goes in we will start to run multiple passes per layer. Each layer will get an additional pass. When you're putting in your fill passes, make sure you're overlapping each previous weld by about 50%. The goal for the fill passes is to get up to flush with the plate or just barely below flush. The beauty of overhead welding is you don't have to go in the same direction on each pass. If you notice that one side is getting a low spot, start at. the opposite side and work your way back on the next set of passes.
Once you're flush, it's time to. throw the cap on. There are a few things you'll want to remember during this step.
Make sure that you break down the top of the bevel and move slow. enough to let it fill in. If you get undercut along the toes of your cap it's going to be a quick fail.
You can have up to 3/16" reinforcement. On a normal 3/8" test you only have up to 1/8" of reinforcement. However, on this 1" test, you c an have up to 3/16". Use it to your advantage!
As you're going through the test, make sure you take your time to clean out ALL slag. You're not going to be able to burn out slag by increasing your amps here. You have to let the plate cool between passes anyway, so use the time wisely and set your next pass up for success. The purpose of the side bend is to check the fusion at every pass, so don't shoot yourself in the foot by forgetting to clean out your welds.