7 replies to this topic

[pete l]

hi all.

 

some of my plug welds are not holding, some of them go pop after and are not welded to the other panel.

 

what am i doing wrong ?

 

Pete

[sonikk4]

Size of hole and power/wire feed speed.

I do not use 5/32 holes, too small and easy to fill with weld rather than getting any penetration. I always use 3/16th or 1/4" holes. A high power setting with wire speed to match.

Having the material clamped together well is also a must.

[finch661]

as above. have a look here

 

 

 

 

 

i always liked the look of  

[pete l]

My holes are 7 mm

I'll keep on trying

[sonikk4]

My holes are 7 mm

I'll keep on trying

 

If your holes are 7mm then you are not using enough power and suitable wire speed. The other big thing i declined to mentioned the metal must be clean of any paint other then weld through Zinc primer if you are using it.

[pete l]

I don't think i need more power as i manage to increase the size of my hole when trying to weld them.

Do i need fast or slow wire speed ?

Ans all clean apart from weld thru

[sonikk4]

If you are burning back then up the wire speed.

[Stu.]

If the hole edges are burning out then the panels aren't tight enough together. You also need a fairly high power setting with good wire speed for plug welding.

 

Start the weld in the centre of the hole, wait to see a nice orange weld puddle then move steadilly in a circle to the outside closing the hole. Look for a small dimple on the rear of the bottom panel, that's a good indication that the penetrations good.

 

Also I have never got on with weld through primer. I find it messes with the weld puddle and and the arc strikes onto the edge of the hole causing it to blow out.

 

I get much better results without using it, but I know others have good results.

 

As you said, practice is the key. It'll click soon enough and then you'll be well away with it.