AWS D1.1 Flux Core Weld Test | Dual Shield

WeldTube
24 Aug 202023:03

TLDRIn this instructional video, welding expert Abraham demonstrates a D1.1 structural test using the dual shield flux core welding process with a backing strip. He meticulously explains the importance of proper plate preparation, tacking, and welding techniques, including zigzagging and weaving to ensure a flush finish. The video showcases the use of the Everlast Lightning MTS-275 machine and offers tips for handling the heat during close-core welding, emphasizing safety and precision for a successful outcome.

Takeaways

  • 🔨 The video is a tutorial on performing a D1.1 structural test with a backing strip using the flux core welding process.
  • 🛠️ Proper preparation of the metal plates is crucial, including grinding off mill scale from both sides to ensure a clean surface for welding.
  • 📏 The importance of correct fit-up is highlighted, as it is a common point of inspection for quality control during tests.
  • 🌟 The video is sponsored by Everlast, showcasing the use of their Lightning MTS-275 welding machine.
  • ⚙️ The welding machine settings are detailed, including wire speed, voltage, and inductance, which are critical for the welding process.
  • 🔧 The use of a backing strip is demonstrated, which is placed between the metal plates to provide support during welding.
  • 👷‍♂️ Tacking techniques are explained, including making multiple tacks to secure the plates in place before the main welding process.
  • 🔥 Safety tips are provided, such as wearing a heat pad on the dominant arm to prevent burns from the welding process.
  • 🧵 The welding technique involves zigzagging and pausing to allow the weld to fuse properly with the bevel walls.
  • 📏 Post-welding tips include cleaning the nozzle after each pass and using good judgment to decide the number of beads needed to flush the plate.
  • 🏗️ The final steps involve capping the weld to ensure a smooth and even finish, with an emphasis on patience and precision.

Q & A

  • What is the main focus of the video?

    -The main focus of the video is to demonstrate a D1.1 structural test using the flux core welding process with a backing strip.

  • What is the first step in preparing for the test according to the video?

    -The first step is to prep the plates by grinding off all the mill scale on both the front and back sides.

  • Why is it important to clean the backing strip before the test?

    -Cleaning the backing strip is important to ensure proper fusion during welding and to meet the quality control standards that may affect the test outcome.

  • What is the purpose of using a test strip in the welding process shown in the video?

    -The test strip serves as a spacer to maintain the correct distance between the plates during welding and also acts as a backing for better fusion.

  • How many tack welds does the video suggest placing on each side of the plate?

    -The video suggests placing three tack welds on each side of the plate, for a total of six tack welds.

  • What welding machine and process does the video use for the test?

    -The video uses an Everlast Lightning MTS-275 welding machine and sets it to flux core mode for the test.

  • What are the initial settings for wire speed and voltage in the video?

    -The initial settings are a wire speed of 260 and a voltage of 24.5 volts.

  • Why is it recommended to wear a heat pad on the dominant arm during the welding process?

    -Wearing a heat pad is recommended to protect the arm from the intense heat generated during the flux core welding process, preventing burns or blisters.

  • What technique does the video suggest to prevent the welder's hand from getting too hot?

    -The video suggests changing the way the gun is held, moving the hand further away from the plate to reduce heat exposure, or wearing an arm pad for better protection.

  • What is the purpose of the inductance setting in the welding machine used in the video?

    -The inductance setting controls the digging action of the weld, which is important for the first bead to ensure good penetration and fusion.

  • How should the welder aim the wire during the root pass in the video?

    -The welder should aim the wire at the very edges of the bevel and use a zigzag technique, ensuring the wire is in the middle of the puddle and not on the leading edge.

  • What is the significance of cleaning the nozzle after each pass in the video?

    -Cleaning the nozzle after each pass is important to maintain the quality of the weld and to prevent any debris or buildup from affecting the welding process.

  • Why is patience important during the welding process shown in the video?

    -Patience is important to allow the puddle to fill up properly and to avoid rushing, which can lead to an uneven weld or other defects.

  • How does the video suggest finishing the weld to ensure a flush surface?

    -The video suggests using good judgment to determine the number of beads needed to flush the plate and adjusting the voltage lower for the final pass to prevent cratering.

  • What is the purpose of the cap pass in the welding process described in the video?

    -The cap pass is the final step to ensure a smooth and even surface on the weld, aiming the wire on the right toe of the previous bead to create a proper overlap.

  • What type of wire and shielding gas is used in the video?

    -The video uses Kobelco 71T wire from Milesteel and C25 gas, which is a mixture of 75% argon and 25% carbon dioxide.

Outlines

00:00

🔧 Welding Test Preparation and Setup

The script begins with an introduction to a welding demonstration video, sponsored by Everlast. The presenter, a supervisor at South Cold One Academy, explains the process of a structural test using a D11 test. This involves preparing the plates by grinding off the mill scale on both sides and ensuring cleanliness. The importance of proper plate preparation is emphasized, as it is a criterion for passing welding tests. The presenter also details the setup for the test, including the use of a backing strip and the correct spacing between the plates.

05:00

🛠️ Demonstrating the DM1 Structural Test

The presenter proceeds to demonstrate the DM1 structural test with a backing strip. He explains the correct way to position the plates with the test strip in between for proper spacing. The importance of a good fit-up is highlighted, as gaps between the plate and the backing strip can lead to failure in a real test scenario. The video also provides tips on how to avoid burning one's hand during close-core welding, such as wearing a heat pad or changing the way the welding gun is held.

10:01

🌟 Root Pass Technique and Tips

The script describes the technique for the root pass in welding, emphasizing the importance of aiming the wire at the very edges of the bevel and using a zigzag pattern while pausing on each side to allow proper fusion. The presenter advises keeping the wire in the middle of the puddle and letting the puddle climb the bevel walls. The use of the Everlast Lightning MTS275 welding machine is detailed, including setting the wire speed and voltage, and the benefits of using the machine's features such as pre-flow and burn back.

15:03

🔄 Weaving and Stringer Beads in Welding

The presenter continues with the welding process, focusing on the second bead and weaving techniques. The importance of relieving pressure on the hand and maintaining a consistent travel speed is discussed. The script also covers the use of stringer beads to fill the space between the plates, with an emphasis on patience to allow the puddle to build properly and the decision-making process when choosing between two wide beads or multiple stringer beads to achieve a flush finish.

20:03

🏁 Completing the Weld and Capping Technique

The final stages of the welding process are described, including flushing the plate and preparing for the cap pass. The presenter shares his approach to deciding on the number of beads needed for a proper flush and adjusting the voltage for the final pass to prevent cratering. The importance of good judgment in welding is stressed, as well as the technique for capping the weld by aiming the wire at the right toe of the previous bead for a straight and overlapping finish.

🎬 Conclusion and Sponsor Acknowledgment

The script concludes with the presenter finishing the welding demonstration and summarizing the process. He acknowledges the sponsor, Everlast, and provides information on the welding machine and wire used during the test. The presenter also offers a promo code for the audience to receive a free noble torch and foot pedal upgrade package when purchasing from Everlast. The video ends with a reminder of the learning objectives and a sign-off until the next video.

Mindmap

Keywords

💡AWS D1.1 Flux Core Weld Test

The AWS D1.1 Flux Core Weld Test refers to a specific welding procedure qualification test that assesses the ability of a welder to perform a dual shield flux core arc welding process. In the video, this test is conducted with a backing strip to ensure the quality and structural integrity of the weld. The test is crucial for verifying that the welder's technique meets industry standards, as seen in the video where the welder meticulously prepares the plates and follows a set procedure.

💡Dual Shield

Dual Shield is a term used in welding to describe a process that uses a shielding gas mixture, typically a blend of argon and carbon dioxide, to protect the weld area from atmospheric contamination. In the context of the video, the welder uses a C25 gas, which is a mix of 75% argon and 25% carbon dioxide, to perform the flux core welding. This dual shield provides a stable arc and good weld quality, as demonstrated in the video.

💡Backing Strip

A backing strip is a piece of material, often metal, placed behind the weld area to provide support and improve the quality of the weld. In the video script, the welder uses a backing strip during the AWS D1.1 test to ensure a flush finish and to prevent any undercutting or gaps that could compromise the weld's strength. The backing strip is carefully fitted and tacked in place before the welding process begins.

💡Prep

Prep in welding refers to the preparation of the materials to be joined, which includes cleaning, grinding off scale, and ensuring that the surfaces are free from contaminants. In the video, the welder emphasizes the importance of proper prep work, such as grinding off the mill scale from both the front and back sides of the plates, as it is a critical step that can affect the outcome of the weld and is often checked during quality control assessments.

💡Tack Weld

Tack welding is the process of making temporary welds to hold parts of a project in place before the final welding is done. In the script, the welder performs tack welds on both sides of the backing strip to secure it in position. This is an essential step to ensure proper alignment and fitment before proceeding with the full structural test weld.

💡Flux Core

Flux core welding is an arc welding process that uses a tubular wire filled with fluxing materials to lay the weld. The term 'flux core' in the video refers to the type of welding process being demonstrated, where the welder uses a flux-filled wire that provides its own shielding gas, eliminating the need for an external gas supply. The welder selects the flux core setting on the welding machine to match the process being used.

💡Inductance

Inductance in welding refers to a property of the welding machine that can be adjusted to control the digging and penetration of the weld. In the video, the welder sets the inductance to 75 for the root pass to ensure good penetration and fusion with the backing strip. Adjusting inductance is a technique used to optimize the welding process for different materials and joint configurations.

💡Zigzag Technique

The zigzag technique is a method used in welding where the welder moves the welding torch in a zigzag pattern along the weld seam. This technique is used in the video to control the weld pool and ensure even distribution of the weld material. It helps to prevent excessive penetration and ensures a uniform weld bead, as demonstrated when the welder performs the root pass and subsequent fills.

💡Stringer Bead

A stringer bead is a continuous, unbroken weld bead that is used to build up the weld joint. In the video, after the hot pass, the welder applies stringer beads to fill the joint and bring the weld up to the surface level of the surrounding material. The welder uses a zigzag motion to apply these beads, which helps to control the size and shape of the weld.

💡Capping Pass

The capping pass is the final pass in a multi-pass weld that is used to create the final surface of the weld. In the script, the welder describes the process of performing the capping pass, aiming to create a smooth, even surface that is flush with the surrounding material. This pass is critical for the aesthetic and structural integrity of the weld, as it is the last layer of metal that will be visible and bearing load.

Highlights

Abraham demonstrates a D1.1 structural test using the flux core welding process with a backing strip.

The importance of proper plate preparation for welding tests is emphasized, including grinding off mill scale.

The use of a test strip as a spacer for the welding plates is shown.

Tacking techniques are explained, including alternating attacks for better plate fitment.

Everlast Lightning MTS275 is introduced as the welding machine used in the video.

Settings for wire speed and voltage are detailed for flux core welding.

The function of pre-flow and its role in controlling wire feed is discussed.

The significance of inductance control for better penetration in the root pass is highlighted.

Abraham shares tips on avoiding hand burns during close core welding with heat pads and proper gun handling.

Zigzagging and pausing techniques for the root pass are explained to ensure proper fusion.

The necessity of keeping the wire in the center of the puddle and allowing it to climb the bevel walls is demonstrated.

Cleaning the nozzle after each pass is recommended for better weld quality.

Weaving and zigzagging techniques for subsequent beads are shown.

The use of stringer beads to fill wider gaps in the weld is explained.

Abraham discusses the importance of patience in allowing the puddle to fill properly.

Flushing out the plate with the final beads and avoiding craters by adjusting voltage is shown.

Capping the weld with proper wire placement and overlap for a professional finish is demonstrated.

A summary of the welding process and the equipment used, including the Everlast MTS-275 and Kobelco 71T wire, is provided.

Abraham concludes with a reminder of the learning objectives and a teaser for the next video.

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