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Ive been researching GMAW Spray transfer welding positions for a WPS I am writing, and can only find the Flat position in the AWS WIT book, but did find Flat and Horizontal in the AWS Welding Handbook 9,Fourth, Part 1. but its in the Stainless section(I’m qualifying Group 2 Carbon), and I obviously found Flat and Horizontal here on your site, can you cite any sources on that information? The Lincoln procedure handbook has nothing on it , thanks for the information.
The reason why the welding position for spray transfer is of concern is due to the fluidity of the puddle. You can’t really run it out of position. It has to be flat and/or horizontal. You can run pulse spray out of position but just for spray it is not really feasible.
For spray transfer the position matters if you are writing a prequalified WPS. You can write a prequalified WPS for spray transfer in the 3F position. The procedure itself will comply to all requirements of AWS D1.1 or D1.6, but it cannot be used in real life because of the fluidity of the puddle. So, I’m assuming your question is more in lines with this.
Some same flat only, other say flat and horizontal. The reality is that it depends on the skill level of the welder and/or the type of joint. For example, a horizontal fillet should be no problem at all. A horizontal groove weld may be extremely difficult to do with spray transfer.
If the questions is more in terms of permissible positions then the answer is that all positions are permissible for a WPS, but not all are feasible for production.
I’ve been signed up for your weekly newsletters for about 5 years now. Appreciate the great content and the relevance to this industry in Canada as well. Thank you!
Thank you for being one of our amazing subscribers and thanks for you note. We appreciate having you.
First of all, thank you for the great content! Second, I have a recommendation on a topic idea. I would like to see a blog post on FCAW-G gas marks (aka worm tracks, chicken tracks). There is a lot of resources out there on what causes them but little to nothing is out there on if they are discontinuities/defects or the acceptance criteria if they are. To be clear I am taking about the striations without piping porosity (aka Wormhole porosity). Thanks
Great question. Worm tracking is a type of porosity and therefore follows the acceptance criteria for porosity. Different materials (and different codes) will have different allowances for porosity. However, due to the size of the indentations when experiencing worm tracking they typically are always repaired. As you mentioned there are many different causes. In our experience they major culprit problems with the filler metal, whether it is moisture, lack of fill or other manufacturing issues.
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Gday Welding Answers, thanks for your work. I have a 45 tonne excavator bucket to repair; HAZ and hydrogen cracking. I can safely assume the material is Bisalloy 80 (although I’m told it could be T1)
material thickness varies from from 10mm to 25 mm.
My proposed weld procedure is:
Essab .9 Aristorod fillerwire 90/10 argon co2 gas.
Gouge out cracks and grind clean, preheat to 40C.
In thick material use double v prep butter up sides for better dilution and avoid introducing hydrogen from the unpreped side. Complete the weld with small multiple passes. When completing the other side gouge back the root to clean material and complete the weld with small multiple passes.
On thinner material with better access gouge and clean both sides, preheat to 40C weld with small multiple passes.
Could you please comment on this procedure.
Thanks
Steve
Hello Steve, your description of the procedures seem well thought out. The preheat for 10 to 25mm looks fine as well. Remember that arc gouging is a thermal process and can also have an effect on the microstructure. So make sure it gets done while the part is properly preheated.
This is a great site.
Thanks Chris! We are glad you find the content valuable.
Can I get details of TIG type welding courses in Germany ?Specifically I am in search of courses having 6 months to 1 year duration , to acquire profound welding skills .
Regards,
Chetan D .Pawar
Unfortunately we do not have any information on courses available in Germany. You can tried contacting the German Welding Society for information. Their home page is: https://www.die-verbindungs-spezialisten.de/index.php?id=dvs-home1
I am having a problem with barrels of wire!
The guys keep complaining that it pig tales when coming out of the gun.
But when I installed a new barrel and the roll is not taken off there is no problem with the one we have hooked up.
My question is if they cut and disconnect the barrel does it break the tension within the barrel with it untwisting with it being slack?
Hello Will,
If you cut the wire coming off the barrel it should not unwind like a spool would. However, the top few layers make loosen up a bit and when feeding again it could cause some issue. It is good practice to cut the wire and then bend it into an L-shape so it cannot go back into the barrel (assuming you have a top hat or other payoff device on top).
In regards to the pig tails. This can be caused by different things. If the winding of the barrel wasn’t done properly by the manufacturer you will get this effect, also called wire flip. Most often it is caused by your wire feeder. If you have a 4-roll wire feeder and the two sets of rolls are out of alignment this will introduce a twist on the wire. This twist will relieve itself either forward (at the gun) or backwards (at the barrel). If it goes forward the welder will notice this and will sometimes cause him or her to miss the joint momentarily. If it goes backwards it creates a tangle in the drum. This would be a type e-script tangle. Called that because the wire bends in the shape of the letter “e”and tangles.
A good troubleshooting step (assuming you have a 4-roll wire feeder) is to disengage the back two drive rolls. If the problem goes away then the problem is with the drive rolls. If it does not it may be the wire.
Also, if you are running long conduits from the drum to the feeder make sure there are not sharp bends, excessive amounts of bend or excessive length of conduit. Hope this helps.
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