A Lesson Learned
quote]I used a Hobart 135 Handler with gas (75/25) and haven't had any problems in welding about anything I want to, sheet metal to frame. [end quote.
I am posting these comments so someone else will not make the same mistake I made and place their life or someone elses life in danger.
The above comment was one I made on another board before I found some BIG problems in my welding skills/knowledge yesterday when I started back working on my frame. By no means or stretch on the imagination would any one in their right mind call me or mistake me for a welder but I can stick things together and most of the time they stay stuck...BUT.........
The frame has been setting in the back of the garage for the last 2 month with very little to no attention while I worked on other projects. Yesterday after dragging the frame back out to start on it once more I made a major discovery that has me second guessing my welding knowledge which is very little.
Even though I had beveled all the edges at a good 45 degrees, welded the frame on the highest settings the Hobart 135 has with 75/25 set at 25psi, .023 wire (which was my first mistake, wrong size I am told, should have been at least .030 wire) I find it wasnt hot enough to burn in properly and here the results of it. I found cracks in every welder joint. Along with poor burn in I make a serious mistake by grinding the welds to have that smooth look when all I did was grind out any weld that might have been holding the frame together.
When grinding out the old welds, the deeper I got into the joint, it looks as if the weld was just setting on top of the metal and not burnt in at all
I am guessing its because the settings on the 135 wasnt high enough amperage.
Heres a photo of the cracked weld joint and one after I ground out all the old weld and rewelded it with the Shopmaster 300 on a 220 amps setting, .030 wire and 25psi on gas. I checked it again this morning and I dont see any cracks yet so hopefully I have repaired what could have been a major health hazard.
If anyone has any suggestions I would appreciate the input and I am sure there are others new welders that would like to hear about this also before they make the same mistake.
Thanks.