Chemtron Corporation “Welding the Flux-Cored Way”

Transcript (Download)

Welding, the joining of two metals with a strong permanent bond.

Welding is one of the major construction techniques used in steel fabricating.

The heavy construction industry and builders of modern high -rise structures are among the many industries that have switched from shielded metal arc electrodes to the gas shielded metal arc or flux cord process.

The gas shielded flux cord process is widely used in heavy weldments of mild and low alloy steels.

The flux cord electrode is an arc welding process for single and multiple pass welding of steels of various alloy content and physical properties.

Spooled or coiled electrodes convey the electric current or amperage for the arc which fuses the material to be welded and at the same time provides the filler metal for the weld.

Both the 332nd inch and 1 16th inch wire are shipped by pallet.

For our work in the flat position we'll be using the 332nd electrode.

The 1 16th is an all position wire.

First check the carton for damage.

A punctured carton could mean a plastic inner liner and a damaged roll.

Then roll the coil free and you're ready to mount it on the wire feed.

We'll also be working with a relatively simple welding system involving a wire feeder, drive rolls, gas and welding gun.

Line up all the holding clamps on the wire feed, mount the coil, and lock the holding clamps into position.

Then cut the first tie wrap.

But be careful not to cut all four tie wraps or you'll get a bird's nest.

That's another way of saying costly downtime.

Line up the loose end of the electrode, trim the end with a wire clipper, cut the second tie wrap, and insert the wire into the drive roll.

Start feeding the wire through the feed cable to the end.

Next, cut the third and fourth tie wraps on the coil.

After tightening the drive roll tension screws, remove the contact tip from the gun.

Load the gun through the inching switch on the wire feed unit or by brief squeezes on the gun trigger to a point where the electrode protrudes from the gas cup by three -quarters of an inch.

Now replace the contact tip.

Remember to set the wire feed speed control to between 38 and 40 inches per minute.

Then check your drive roll tension.

Too much tension and you'll get a file action on the electrode.

Tighten the tension nut with your fingers and feel the wire as it runs.

Your fingers should drag on the wire.

Checking your gas flow is a simple procedure of squeezing the welding gun trigger and checking the meter.

Make necessary adjustments on the flow control so that the meter reads 45 cubic feet per hour.

That's the recommended setting for 332nd wire.

Welding amperage and wire feed speed depend upon the particular application and specification established by the welding engineer.

Adjust your feed speed to these guidelines.

If in doubt, check your consumable catalog.

The area you are welding, the weld zone, is protected from atmospheric contamination by carbon dioxide shielding gas and a molten blanket of dense but easily removed slag.

The electrode stickout should be three -quarters to one inch beyond the gas cup and one and a quarter inches beyond the contact tube.

Excessive electrode stickout could cause poor gas shielding and pinholes in the weld.

Correct guide tube placement and proper positioning of the nozzle results in x -ray sound welds.

A leading angle to the gun of two to fifteen degrees gives a lagging gas shield.

The same leading angle technique is used in fillet welds as with flat welds.

When making fillet welds, position the electrode 35 to 40 degrees from the vertical plane.

Now you're ready to begin welding with this five -step sequence.

After you've turned on the power source and adjusted the voltage range, turn on the CO2 shielding gas.

Adjust the regulator and flow meter and set the wire drive speed.

Lower your helmet, position the gun, squeeze the trigger, and start an arc.

Bead size is determined by the welder's rate of travel on the workpiece.

It has a marked effect on weld penetration and bead appearance.

Here's what happens when speed is reduced to the point where the molten metal, the weld metal, and slag flow into a crater beneath the arc giving an insulating effect between the arc and base metal.

Note the bead appearance and shallow penetration.

In this instance, the rate of travel was adjusted to give the best combination of bead shape and penetration.

Deposit a bead too fast and penetration is reduced while bead appearance is smaller with a slightly convex surface.

There is also the possibility of undercut.

Remember, deep penetration of the flux -cored electrode reduces your edge preparation for butt joints.

But deep penetration also means less welding time to achieve comparable strength and load carrying capacity.

To these features, add simplicity and you have one of the most popular welding processes today.

Identifier

F.2010-01-0220

Abstract

A sponsored film made by the Goldsholl Associates for the Chemtron Corporation's Welding Products Division based out of Chicago, Illinois. The film focus primarily on Welding, or more specifically the gas shielded fluxcore process of welding. Includes scenes of Chicago high-rise buildings

Run Time

0:06:39

Format

16mm

Extent

250 feet

Color

Color

Sound

Optical

Reel/Tape Number

1/1

Has Been Digitized?

Yes

Language Of Materials

English

Element

Print

Genre

Industrial
Sponsored

Form

Short

Subject

Industry

Related Collections

SERIES I: Goldsholl Design & Film Associates Films

Related Places

North America ➜ United States ➜ Illinois ➜ Chicago

Sponsor/client

Chemtron Corporation

Main Credits

Goldsholl Design & Film Associates (is production company)

Chemtron Corporation (is producer)

Do you know more about this item?

If you have more information about this item please contact us at info@chicagofilmarchives.com.