volts E81T-1 PF T-fillet

Been bit of trouble at site I go to knowing what to do with E81T-1 (Rutile Flux-Cored Arc Welding (Rutile Flux-Cored Wire)). Positional welds - all positions.

So been trying some weld conditions.

1.2mm (48-thou-inch) wire Gas 100%CO2 - as recommended for the wire. 20mm / 3/4inch stick-out works well and allows plenty of sight of weld-pool&bead. Going for stringer-bead absolutely straight run. Welders are having to weld in some awkward restricted-access locations, so want the technique to be simple - squeeze the trigger and go - all concentration can go on following the weld. (???) Also keep the properties high - toughness and strength.

Problem is the variability of the welding machine. Expected this fairly expensive quite modern kit would be very stable but no, Amps +- 10A and V +- 0.5. (surprised - with copper-and-iron machine, a slight tweak on the wire feed speed "pot" would keep the conditions sweet with varying line-voltage, etc) Can have a perfect weld then pick up the torch a few minutes later and its humped - would have to spot that the change has happened and oscillate to flatten the bead - or tweak the volts.

"Perfect" for PF is showing about 200A 25V to 215A 25.2V. (not checked with calibrated meter, but machine claims to be calibrated) "Perfect" as in flat bead well fused-in at edges, no other shape problems across or along.

My thought is - with this wire, higher volts has little negative effect (???) At worst, groove in front of weld finish when 3V or 4V "over". No toe-groove ("undercut") or anything. So good strategy is find your "perfect" conditions then set 1V higher so the weld stays good on the "downs"???

Really do not want to burden the welders with having to spot that the conditions the machine is giving has changed. Back to original point - want them to be able to point the torch and go...

Any wise advice for this case?

Rich

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Richard Smith
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