Ive been practicing welding and making a chair. I had trouble getting the 16 gauge sheet to stick to the 1/8" angle iron I was using when trying to fill 1/8" holes I was drilling. So I drilled a 5/16" hole in the sheet to get a better penetration and puddle on the angle iron. My problem is when I ground it away there was a black outline that was like a divot around the perimeter. I had the welder set for 1/8" so now what I did was set it for 16 gauge and try to fill that divot and regrind. This didnt solve it. I pretty much lightly warped the 16 from grinding so much I think.
Im ***uming this means the puddle was too hot for the 16 gauge and burned it. How can I remedy the problem now? (Fill the divot)
If the metal was too hot it would have not welded together. That dark spot around the hole is probably due to dirt, paint or oil that was on the metal before you welded it. Are you using tig, mig or stick?? Opening up the hole size should help you on penetration. Good deduction.
Flux core is alittle harder to keep inclusions out of the metal but you should be able to handle that. Just be sure both metals are squeaky clean. Try it again.
I flap disked the **** out of it (although the disk is worn out). Maybe a new one will work. It doesnt really want to reach down into the black divot
As you discovered, you need a big enough hole so that you can get the base metal hot enough to melt, but then you also have to be careful not to get the sheet metal too hot. I usually do these type welds in stages, I'll get one or two spots tacked, then go back and fill in. But I don't use flux core, so I don't have to chip off slag between welds, like you will. And getting sheet metal hot enough to fill in a weld that big, you're going to get some warpage.
Get some s**** and practice- start in the middle of the hole and wash the puddle onto the sheet metal , but it needs to be tight. Fill the hole up. I think you'll have trouble getting a nice perfect metal finish with FC anyway.
The chair looks like an accident ready to happen The sharp corners will puncture or cut someone. If you have access to a bead roller you could fix it.
Its not done yet. I dont have access to a bead roller but i'll soften all the edges with my angle grinder.
Thanks. I was able to clean that black slag surround with a wire wheel on my cordless drill. Tomorrow when its warmer and I have better light I'll refill and regrind and see what I get.
Sometimes when I am plug welding I take a little extra time and mark a small divot in the heavier base metal. then when I am filling it I get a little better penetration. One thing that I have learned about angle iron over the years is that most of it is hot rolled and it dirty as hell, mill scale will hold a lot of ****. grinding it to clean it is the best option if you want a clean weld.
Yeah - its in the 20's.... I suppose a little propane wouldnt hurt. Although I did get good penetration this time
Be sure you have it clamped very good , if the 16 ga. lifts off the angle it will burn thru .With fc be sure it is very clean .
Yeah being that the panels are riveted together some sections were a little higher off the angle iron due to the back of the rivet touching. Just an amateur mistake on my part. Luckily thats mainly in the front where I wasnt really welding. Still effected other areas. Its been too damn cold to work on it lately though, itll have to wait. Thanks all
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