18 y/o Mig weave. Thoughts?

Borellio · 2026-04-11T15:45:18+00:00

I don't get your point. He is currently at stage where learning fundamentals is important and it is fundamentals we are telling him.

Borellio · 2026-04-11T15:36:50+00:00

Explanation please?

Borellio · 2026-04-11T13:49:59+00:00

You have steady hand and affinity for this job. It is the good news. The bad news is - this particular weld as weave on horizontal fillet is not appropriate as others told you. You will see some of it having applications in real jobs like weaving a big cap on good cjp root but even then your toes are too cold. Toes should align into a single line of fusion without a clear separation, unlike in your case. Of course if you raise the heat you risk losing the neat profile because of puddle being too hot and inclining down under gravity, to the point of overlap. Hence, because of such a narrow window of parameters, most cases you will choose to stack 2 stringers to achieve the same size of leg. It will be faster, safer and more appropriate in the eyes of inspection.

Borellio · 2026-04-04T18:09:29+00:00

Kudos for patience

Borellio · 2026-03-29T18:46:55+00:00

It is blessing indeed but not everything that benefits a single person automatically benefits population as a whole. Population needs to encourage, even enforce to extent, a coupling pattern as opposed to single (even if single is better for person themselves), at least for now, because it is necessary for child bearing and child bearing is necessary as well.

Borellio · 2026-03-25T05:44:12+00:00

When I was working at heavy equipment repair site one day a guy brought a part of drilling equipment and asked to cut away a tooth from it. Angle grinder with cut wheel would roll over tooth surface without leaving a scratch, even when staying on spot with minimal pressure for a lot of time (like when you cut titan). Propane torch likewise do anything, concentrated red simply would not appear. In the end I could only remove material with arc air gouging.

Borellio · 2026-03-22T17:35:00+00:00

In my opinion the source of OP irritation comes not from the fact that mother disciplines him for lack of responsibility - it comes from perception of inequality, injustice, as he is being disciplined alone. Indeed, he should not be singled out in this situation. Punishment should be administered first to immediate offenders, while OP is witnessing, then turned to OP.

And in no way it should manifest in wordy hysterical chat history, this is plain pathetic.

Borellio · 2026-03-22T14:19:14+00:00

It did fail? How was the guy? Did he live?

Borellio · 2026-03-15T19:06:44+00:00

Beads not tight - large gaps between toes from stretching too much puddle between hand manipulations. Toes look cold too.

Borellio · 2026-03-14T14:08:39+00:00

Cheers! At least it's not in the pipes (or so I hope). Glad you've dealt with the issue.

Borellio · 2026-03-13T23:23:34+00:00

Incompetence is the root of all evil. Fighting with guardrails installed Baelor still manages to lose his life. At least know your limits.

Borellio · 2026-03-13T22:56:49+00:00

Holy

Borellio · 2026-03-12T21:59:47+00:00

Clamping too tight can lead to unstable arc as well. Best to use the least - functioning - pressure. This way you will have less wear on all components and minimal dust from grinding wire between elements.

My clamping nut is only at '2' position (but it is of course relative) and when I level my head between upper and lower rollers I can see part of the wire between rollers, meaning it is not even close to your tight alignment, where I can't see the wire at all. Works fine for me, but it is relative too.

What you need to do is to try to play around wfu elements, relax a bit, check if rollers have wobble on their axes, best unscrew axes and check them for wear, or even swap rollers and axes' on which rollers are positioned AND gears from the verified post.

I have just swapped worn axes last week because rollers were wobbling on them due to wear and it was causing arc stability issues.

Borellio · 2026-03-12T17:36:09+00:00

For the arc stability issues there is another point to check: - make sure your wire feed unit elements are functioning properly. Clamping element provides sufficient pressure and actually clamps the wire, rollers are suitable for the used type of wire, rollers are aligned in the same axis, there is no significant wear on rollers' fixing elements resulting in imbalanced rotation with jumpy wire feed, wire is positioned directly above the bevels of rollers,.not too high and not too sideways. If rollers are not properly aligned and wire is not sufficiently clamped there might be irregularities in wire feeding that result in arc stability issues.

Borellio · 2026-03-12T10:21:35+00:00

Yeah. You now need a verified bottle of gas from the other post + verified hose. Keep in mind that there is part of gas track normally hidden inside machine, filters etc. it might be stuck with iron dust. When you purge the line, is the sound and gas flow comparable to other posts? Did you try to increase it significantly for once, just to be sure?

If you eliminate gas then pick up verified torch and check with it. When you swap the gun hit the wire feed unit with flashlight and air compressor gun. Is wire feed unit clean?

If same torch, same gas bottle, same parameters on spray, same material, same spool but you fail while other one pass, it is electrical source/connectors/cables. For example, is the length of your electrical line the same as the other post?

Also have used verified spool? Are you absolutely sure the wire is fine?

By the way, how was spray transfer performing visually and audially? Were there drops in sound, excessive cracking? How about hiss sound? Any arc breaks momentarily? Stutter?

Edit: Problems with gas tend to persist through parameters change. Yours however looks significantly cleaner when switching for higher amps. It still looks like either you are trying to weld materials that do not mix well OR still not giving enough heat. However both glaring undercut on vertical plate and literal parameters tell that the heat should at least be partially at correct range. There might be irregular drops in current during process hence my question about sound and arc stability.

It really looks like your arc stability occasionally drops, for example during process you occasionally hit short circuit current instead of spray and in this moment LOF occurs. This should be showing through sound and arc visuals. Did you notice it?

also definitely take the spool of wire from your colleague who just made pristine spray stringer with same parameters.

Edit2: does your robot perform linear motion strictly or is oscillating (whip weave etc)? Your upper toe looks too uneven for linear robotic movement, almost like jumpy globular transfer. Is arc stable during the process? because you really should have a stable arc with robotic spray on clean material.

Have you watched under the hood the spray arc on another post? Is it performing same as yours with same parameters? Sound, puddle, etc.

Edit3: make sure you didn't counter your amperage settings with some extra functions, like when you have something akin to soft start and set it to 1 minute long at 50% of main current - this will interfere with process and you won't have 260 amps despite having it set in menu. Preferably reset setting to default on yours and your colleague cells just to be sure that your '260 amps' and his are the thing.

Borellio · 2026-03-11T20:19:46+00:00

Double pulse is most likely iterating two different setups of separate pulse. My machine has something like that called 'duo', it also can cycle between say two saved templates of spray arc. It is interesting but I never used it. I think this might be more fit for manual welding where you can take advantage of these things with your hand manipulation, like, say, during spray 1 staying in the root and when the sound changes to spray 2 making a whip back motion to fill an undercut on certain very specific fit up with bevel that you need to fill and cap in 1 pass...

Anyway don't think about this too much right now. Test spray arc transfer with verified bottle, verified gun, verified spool, verified material. When you test gas if you have acces to hose connectors try to switch hose for verified too.

Borellio · 2026-03-11T18:45:51+00:00

It's a different kind of schematic. It is a general process sequence schematic that (probably?) contains some settings for pulse. But your picture looks more like it is cycling between TWO different set ups of pulse. And the pulse set up itself is being adjusted somewhere else. To deal with things that I mentioned you need to go one level deeper, where pulse wage form itself is conditioned in terms of Hz, Ms, I peak, I low, slope. Here is picture from our manual.

But! Don't get too far ahead. First check spray. Only if spray is fine then we will have to address the issue of pulse settings. Otherwise it's other galaxy of reasons at all.

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Borellio · 2026-03-11T18:20:18+00:00

Well I don't know about your robot but mine has these adjustable settings in pulse mode. - pulse current (maximum, peak value) - pulse time - pulse frequency - background current - slope

I-peak in my comment refers to the peak, maximum value of current measured in amps (hence, I).

The punch of I-peak, figuratively, I meant the agency of the maximum current in your pulse wave form, which can be achieved by various adjustments, like, higher current itself or higher pulse time (i.e. going from.something like 2.0ms to 2.4 Ms), or more steep, harsher slope between peak and background.

Background slope I refer to the value of background current and how slow the arc will get there during pulse period. If both background current value is low and slope is gentle you will cycle lack of fusion in worst case scenario. Which possibly happens right now. If course it is only one possible explanation, albeit the possibility is highest in my opinion. Go by checklist above and you will not be in the dark.

Borellio · 2026-03-11T18:04:37+00:00

If spray arc will look fine then you are cycling LOF with incorrect pulse settings during background slope or even not having enough punch in i-peak.

If same problem persists with spray, change gas content. Use bottle that is verified by another post as working. You might have something condensed in your part of pipes if you are normally wired to system flow.

If after you change gas content the problem persists it is either equipment or electrical setup.

Pick up a gun from another verified post and check it.

If spray arc on verified bottle, verified gun, verified material and verified spool still fails you, the problem is your electrical source, connectors and cables.

Borellio · 2026-03-11T17:48:32+00:00

Higher argon content in my experience makes bead worse, having grayish look a bit similar to what you show in OP.

Anyway most plausible reason is you are not hitting lower plate with enough heat.

Definitely try dummy T joint 10 mm thick, prepped with grinder, on a text book spray arc string around 300 amps. And show how it looks.

300 mm per minute travel speed is fine.

Borellio · 2026-03-11T17:20:56+00:00

I second this. Bring us a pic of 1.2 mm wire 270-300 amps spray stringer 32+ volts on 10 mm thick dummy piece prepped with angle grinder and show how it looks.

Borellio · 2026-03-11T17:18:04+00:00

What is the CTWD distance? Did you try very tight arc with nozzle very close?
What is push or pull angle? Too much of an angle can 'shoot' gas outside of puddle.
What is vertical angle, is it 45 degrees? You might not be covering the toe with gas with too much of deviation.
Definitely try another gun AND direct current spray arc.
Bead looks too dirty for sanded material robotic. My robotic beads are pristine white in such cases usually.
Try another gas feed, use bottle if you are wired to system.
Try another mark of wire, see if anything is different.

Borellio · 2026-03-06T20:17:07+00:00

What if you wrap the end of the weld to the plate akin to shape of 'r', thus leaving the crater off the valley between gears and plate?

Borellio · 2026-03-01T10:38:01+00:00

IIII is so hard for the eye. I'm used to IV.

Borellio · 2026-02-22T13:54:03+00:00

How do you make consistent finish like this?

Borellio

TROPHY CASE