minimum weld size 1

[mineweld]

Is there a minimum weld size allowed when using 1/16 dia. metal cored wire?

 

[ajh1]

Minimum weld size is more generally controlled by the thickness of the material being joined. If you try to put too small of a weld on a thick plate, you don't get sufficient heat input to make the weld "stick" to the underlying material.

 

[mineweld]

Thanks for the reply ajh1. My company is trying to use 1/16 wire on 1/4" plate and that calls for a 3/16" weld bead. I was wondering if 3/16 is too small of a bead to try to get with 1/16 wire on 1/4" plate.

 

[metengr]

mineweld;
I would use 1/8" diameter wire for what you need to accomplish.

 

[racookpe1978]

You used the term "metal cored wire" - as if this were MIG welder. True?

(Metengr: A 1/8 rod (SMAW ?) seems to be very large for a small 3/16 fillet on a 1/4 plate base metal. For a 3/16 fillet weld, most of my commercial welders prefer to use the smaller diameter (usually TIG) rods.)

 

[metengr]

racookpe1978;
Yes, the 1/8" diameter would be max for SMAW for this size fillet weld.

 

[mineweld]

Sorry for the confusion, the wire I was talking about is a 1/16" dia, metal cored, tubular, GMAW wire. were using the 60# spools.

 

[Mr168]

You'll never move fast enough to consistently produce 3/16 fillets with a 1/16 wire. Even with .045, you will likely still see oversized fillets.

 

[DVWE]

I agree with Mr168.

You should look at the data sheet provided by your filler metal manufacturer. They will usually provide this type of information on them.

 

[racookpe1978]

I'd think a an 0.035 (maybe 0.030) MIG wire would be be a good choice for a small 3/16 fillet.

But that's based on a my experience with solid wire (gas shielded) so a flux-core slighly larger diameter would probably have about the same amount of metal deposited "per sec" into the puddle.

 

[dbooker630]

The pocket-size Millermatic Calculator recommends .035" or .045" MIG wire for 1/4" thickness. It also recommends .045" or 1/16" FCAW wire for the same thickness. I would go with the smaller diameter but wire speed and voltage depends on whether you desire short circuit or spray transfer. With .035" MIG the calculator suggests 360-380, 180-190 amps, 21-22 volts, C25 shielding for short circuit or 400-420 IPM, 200-210 amps, 24-25 volts and Ar98-2%Oxygen shielding for spray.

 

[vesselfab]

For Flux-cored wire 0.045" you will have a hard time getting a welder to move fast enough for 3/16" fillet.

perhaps the GMAW would be a better choice

 

[flash3780]

A good answer to your question would probably be found in the AWS Welding Handbook.