blowing holes in sheet metal flux welding I am a novice weldor restoring my 1953 MG YB. I'm finding that whenever I attempt to weld new metal to the old I am blowing holes in the old metal. I am scrupulously cutting out rust and grinding the surface clean. If you’re making a DIY heat shield, I suggest using 1-1/4″ long stainless machine screws with 1″ ceramic or steel heat shield spacers between the sheet metal and the stove. If you want to paint the screw heads and the shield to match the stove, use Stove Bright Flat Black .
0 · welding holes in old metal
1 · flux wire for thin metal
2 · flux core welding wire
3 · flux core welding
4 · blowing holes in metal
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Yesterday I was welding some exhaust tubing and had trouble blowing holes in the material. Welder set to MIN and speed anywhere between 6-9. Eventually got the job done with the original HF wire but wasn't pretty.Instead of using flux-core on thin sheet metal, use 0.023 solid wire and C25 . Instead of using flux-core on thin sheet metal, use 0.023 solid wire and C25 gas. No flux residue to clean up, should be less spatter, cleaner welds all around, and you can do .
Single spot welds is the best method for welding thin panels. You could also switch from using ER70 wire to Silicon Bronze MIG wire. This allows you to use much less heat, . I am a novice weldor restoring my 1953 MG YB. I'm finding that whenever I attempt to weld new metal to the old I am blowing holes in the old metal. I am scrupulously cutting out rust and grinding the surface clean. The problem occurs when a weld penetrates completely through the material, either leaving a hole or enlarging the weld area. This is a common issue, especially when welding thin materials like patch panels or other forms .The excessive heat can easily blow holes through sheet metal or lead to warping. There is also more spatter and slag formation using FCAW which can cover small holes on the welded metal creating further issues.
Set machine for 45-50 amps and you should be able to fix up holes in sheet metal. If you don't have any metal to patch, you can always do field filler, break the flux off another rod , and use as filler. I am finding that the welder tends to blow through a bit even though I am on the lowest setting (Hobart Handler 120 using flux core wire) but some sticks on the edge of the .Once you start blowing holes your volts and wire speed (amps) is too high for the caliber of the sheet metal. The spatter can be a sign of a bad ground in your work area, make sure your . Still, it’s possible to weld thin sheet metal using the MIG (GMAW), TIG (GTAW), and stick (SMAW) processes. But MIG and TIG provide the best results. This article will teach you .
Yesterday I was welding some exhaust tubing and had trouble blowing holes in the material. Welder set to MIN and speed anywhere between 6-9. Eventually got the job done with the original HF wire but wasn't pretty. Instead of using flux-core on thin sheet metal, use 0.023 solid wire and C25 gas. No flux residue to clean up, should be less spatter, cleaner welds all around, and you can do the thinner stuff easier.
Single spot welds is the best method for welding thin panels. You could also switch from using ER70 wire to Silicon Bronze MIG wire. This allows you to use much less heat, softer metal for grinding afterward, and produce less warpage. Have a wet rag nearby and pad the metal after a few spots to help soak some heat out as you spot weld along. I am a novice weldor restoring my 1953 MG YB. I'm finding that whenever I attempt to weld new metal to the old I am blowing holes in the old metal. I am scrupulously cutting out rust and grinding the surface clean. The problem occurs when a weld penetrates completely through the material, either leaving a hole or enlarging the weld area. This is a common issue, especially when welding thin materials like patch panels or other forms of sheet metal.
The excessive heat can easily blow holes through sheet metal or lead to warping. There is also more spatter and slag formation using FCAW which can cover small holes on the welded metal creating further issues. Set machine for 45-50 amps and you should be able to fix up holes in sheet metal. If you don't have any metal to patch, you can always do field filler, break the flux off another rod , and use as filler. I am finding that the welder tends to blow through a bit even though I am on the lowest setting (Hobart Handler 120 using flux core wire) but some sticks on the edge of the hole and go inward with mixed success.
1. Filling holes - I've experimented (on test pieces) with the copper piece backing the hole to be filled technique and for whatever reason I'm fairly certain having the copper there actually increases blow through (even if the welds are short bursts).
Once you start blowing holes your volts and wire speed (amps) is too high for the caliber of the sheet metal. The spatter can be a sign of a bad ground in your work area, make sure your ground clamp is held properly in a clean area. Yesterday I was welding some exhaust tubing and had trouble blowing holes in the material. Welder set to MIN and speed anywhere between 6-9. Eventually got the job done with the original HF wire but wasn't pretty.
Instead of using flux-core on thin sheet metal, use 0.023 solid wire and C25 gas. No flux residue to clean up, should be less spatter, cleaner welds all around, and you can do the thinner stuff easier.
Single spot welds is the best method for welding thin panels. You could also switch from using ER70 wire to Silicon Bronze MIG wire. This allows you to use much less heat, softer metal for grinding afterward, and produce less warpage. Have a wet rag nearby and pad the metal after a few spots to help soak some heat out as you spot weld along. I am a novice weldor restoring my 1953 MG YB. I'm finding that whenever I attempt to weld new metal to the old I am blowing holes in the old metal. I am scrupulously cutting out rust and grinding the surface clean. The problem occurs when a weld penetrates completely through the material, either leaving a hole or enlarging the weld area. This is a common issue, especially when welding thin materials like patch panels or other forms of sheet metal.
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The excessive heat can easily blow holes through sheet metal or lead to warping. There is also more spatter and slag formation using FCAW which can cover small holes on the welded metal creating further issues. Set machine for 45-50 amps and you should be able to fix up holes in sheet metal. If you don't have any metal to patch, you can always do field filler, break the flux off another rod , and use as filler. I am finding that the welder tends to blow through a bit even though I am on the lowest setting (Hobart Handler 120 using flux core wire) but some sticks on the edge of the hole and go inward with mixed success.
1. Filling holes - I've experimented (on test pieces) with the copper piece backing the hole to be filled technique and for whatever reason I'm fairly certain having the copper there actually increases blow through (even if the welds are short bursts).
welding holes in old metal
flux wire for thin metal
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blowing holes in sheet metal flux welding|flux core welding