Hi. I am just learning how to stick weld, and I have been having some problems with grapes (I think that's the correct term). I have tried running stringer beads on scrap plate and bar, which seems to be the first training lesson, and these seem to be working out OK. They are straight and clean, and seem to have decent penetration.
So, I tried working on a real job. This was welding a slotted brace to a steel strip. The strip was a few feet long, and the brace was
1.25" x 4" with a slot in the middle. Both pieces were 3/32" thick. The brace was kind of ragged, being made with blacksmithing techniques (sequential application of slotting punch, and knocking the biscuit out from the back side). So, it was a little ragged. There was about a 1/32" gap in the middle, and I tried to fillet weld the piece with 3/32" 6013 with AC. Tack welds worked fine, but when I tried to run the bead, I burned a hole through the place with poor fitup. I probably need to improve my hot punching technique, or use a swage. Anyway, there was a post on USENET, I believe by Mike Graham, saying that blow throughs can be fixed by sweeping the rod back to the hole, then backing off to allow it to cool. This would be repeated until the hole was filled. Although this technique seemed to work, and it filled the hole (sort of like an interrupted whipping motion), it produced these hot sizzly balls which landed on the metal. These things were HOT, and some of them landed on the work surface and burned for awhile. After everything cooled, they turned out to be metal balls which stuck really hard. They are really ugly, and not like slag balls, which can easily be chipped off with the hammer. When you file them, they turn into raised half balls with a shiny top face, still really ugly. They don't seem to affect the strength of the weld, which works out, but is there any way to avoid them? OK, don't blow through, and try to achieve good fitup, but once the deed is done, is there a way to avoid producing these things. Oh yeah, they look like they will burn through clothes/gloves.Thanks, Eric