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HOW TO WELD
A. Welding
position
B.
All metal can be fuse welded with no filler rod. Must have a
good fitup of metal. Aluminum will need flux on the metal & welding
rods. Bring metal to molten - Keep end of flame tip within 1/8" of
metal. Use small circular motion to control puddle. Length of flame cone
will determine how fast to move flame cone. Fuse weld is not as strong as
putting welding rod in molten metal as you join your pieces of metal
together. Use carburising flame to stainless - use inner cone to fuse weld
with.
C.
Brazing - use JOF neutral flame. The brazing of metal is
usually 800 degrees or less. Use low melting rods for the appropriate
metal. Do not overheat material above flow temperature of rod.
D. Steel
-
Thin sheet
metal - use 0 or
1/2" tip (can weld in all positions)
Method 1 -Select the right welding rod (see rod selection). Set
torch to (JOF) neutral flame. Bring metal to melting point adding
filler rod (dip in dip out method) as required. The hotter the flame
the faster you will have to move the rod in and out.
Method 2 -You can also lay rod on top of metal to be welded.
Put welding cone on top of welding rod and flow into metal. Walking up the rod and melting in to the metal using small
movements, keeping flame cone close to metal. Make sure welding puddle
is melting and spreading out. The welding rod is
absorbing 30-40 % of heat. On long welds of sheet metal, tack weld,
space metal 1/16" to 1/8: and skip around on welds to minimize
distortion. Can hammer weld and move metal because of self-annealing
of welds.
-
Thick
Steel - (can weld
in all positions) Choose the no. 2 or 2 1/2 tip. Must bevel all metal
over 1/8 of inch to insure proper penetration of filler rod. Turn
torch to highest heat cone setting and heat metal on both sides till
metal turns red. Turn flame setting down and push welding rod in
molten metal and use circular motion to flow rod in molten metal. As
rod melts to bottom of tapered metal, keep pushing rod in to molten
metal until you get the desired filler height. You can make several
passes to achieve this.
E. Aluminum
-
Thin
Aluminum - best
welding in the flat position, out of position weld requires extra
practice. See rod selection for material being welded. Use 1/16"
- 3/32" TIG rod and high heat flux. Flux must be used with a
special filter lens.
Aluminum welds better if cleaned but you can weld dirty aluminum with
the Henrob. Mix flux and a little water and rub a thin coating of flux
on the rod. Use a JOF neutral flame. Make sure you wash the flux off
your hand and the welding piece with soap and water after welding.
Preheat metal just a little. The larger the piece to be welded the
more preheat. The aluminum starts to melt (usually a jello-like
wrinkling appears), apply filler rod with flux to molten metal. You
might have to touch the rod in the molten metal several times before
you can get a puddle started. Use a dip in dip out method. Keep the
torch flame cone close to the metal. The speed that you dip the
welding rod in and out depends on how fast the rod melts. If the rod
is melting too fast turn the heat down. If you blow a hole in the
aluminum or if you're fixing a radiator coil, circle on the hole and
keep pushing the rod down till it starts to melt. Then keep all the
heat on the rod until it flows in. Pull off the side (weldingcone)
slowly to keep from leaving a pinhole in the weld puddle. If you are
trying to weld aluminum and the welding rod balls up, you're not hot
enough.
-
Thick
Aluminum - use
right welding rod for material being welded. Use high heat flux and
special lens for welding aluminum. Use JOF neutral flame. Use
1/8" diameter welding rod. Turn torch to highest heat using the
no. 2 or 2 1/2 tip. Bevel or grind pieces to be welded to get proper
penetration. Hold the welding cone close to the metal to welded and
preheat at least 400 degrees. Heat the metal where you want to start
the weld. Once the metal starts to wrinkle or melt, lower the flame
cone. (Bring the length of flame cone down to where you can control
weld puddle.) Once metal starts to wrinkle or melt, push rod in and
out of weld puddle. Can use a circular motion. Can make several passes
if needed. If welding rod is balling up, the base metal is not warm
enough.
F.
Stainless Steel -
thin or thick
All positions, use
carburising flame (excess acetylene) weld with inner cone. Outer flame
should be at least twice as long as inner cone. Leave metal with at least
1/16" - 1/8" gap between metals to be welded. Use proper
diameter rod. Lay rod on top of metal to be welded. Put inner cone on rod
and melt into molten puddle. Walk inner cone up rod and into metal. The
amount of heat you use determines the penetration. When finished you will
have a dark looking weld. Jeweler's rouge will polish this up very nicely. G.
Cast Iron - thin or
thick
Weld in the flat
position if possible. Out of position will require additional practice.
Use JOF neutral flame. Use proper rod and high heat flux. Must preheat
metal. Gring crack out. Heat rod and stick in flux. Heat metal and apply
rod to molten metal. Penetration of welding rod is controlled by the
amount of heat on molten puddle. (longer heating in molten puddle will
give more rod penetration). Must postheat all of cast 4-600 degrees and
let cool slowly. (Put sand, lime, etc., if possible. If cast rod is used
you can drill, tap, or gring weld area. H.
Chromoly
Use JOF neutral
flame. Proper tip and rod. Must preheat. Tack weld tubing first. Can heat
metal and use a dip in dip out method or lay rod on tubing and use small
circular motion - melting rod into molten metal. Post heat.
McGill
Distribution
P.O. Box 1057 · Simpsonville, SC 29681
(864) 616-9747
Email: sales@portableweldingtorch.com
   
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