Wire Welding – Tools and Techniques

Equipment and Tools

In wire welding, the equipment and tools that are required are:

Power source welding machine – complete with welding gun and gun cable assembly; automatic wire feeder and control system; and ground cable and clamp
Shielding gas system* that consists of a gas cylinder, regulator, flowmeter and gas hose
Wire cutters, chipping hammer or chisel, and wire brush
Proper clothing including helmet and gloves

*Not required for Fabshield 21B.

Helpful Hint #9

While welding, be sure to keep your gun cable as straight as possible to avoid erratic arc behavior.

Automotive repair using the Millermatic 211 and HB-28 solid wire

Techniques

To produce a good quality weld, it is important to master the following wire welding techniques. However, before starting any welding project, make sure the workpiece – the item you are welding – is as clean as possible. Use a clean cloth, wire brush or sandpaper to remove rust, dirt, paint, grease, oil or any other contaminant. Do not use cleaning solvents because you run the risk of an explosion or fire, or illness from toxic vapors.

Wire Polarity

Be sure to check the wire manufacturer’s instructions for wire polarity and set the power source accordingly. If the power source is not set for the proper polarity, you may end up with a poor quality weld.

HB-28 solid wire requires the power source to be set for DCEP (DC current, electrode positive) or else the weld may lack penetration and have poor appearance due to excessive spatter.

Fabshield 21B wire requires the power source to be set for DCEN (DC current, electrode negative); otherwise, the weld may be porous and produce slag that is difficult to remove.

Shop repairs made easily with Hobart’s HB-28 solid wire

Wire Feed Speed and Voltage

Select the proper wire feed speed (amperage) and voltage based on the specifications of your wire electrode. Sometimes, you may need to “fine tune” the settings. The best way to check wire feed speed and voltage settings is to perform some test welds on scrap metal and check the weld. Be sure that you…

do not use wire feed speed that is set too fast as it will cause too much metal to be deposited, wasting filler metal or resulting in possible burn-through;

do not use wire feed speed that is set too low because it will produce a weld that doesn’t penetrate or fill the joint properly and may cause the wire to “burn back” or melt at the tip;

do not use voltage that is too high because it will create a flatter, wider weld bead that is porous, plus excessive spatter. In addition, high voltage can cause undercutting, a groove melted into the workpiece that doesn’t get properly filled with weld metal;

do not use voltage that is set too low or the weld bead will be narrow and lack proper penetration and fusion.

Helpful Hint #10

Listen to the arc for an indication of whether or not you are welding properly. A good arc sound is one that is consistent and sounds like bacon frying. If you hear excessive popping and cracking, it’s a good indication that the electrode is sticking too far out of the gun or the wire feed speed is too fast.

Helpful Hints Basic Welding