What welder do I need?

[Sberry]

Here is one for Dan, I weld a 2 inch bale spear on where it had work hardened and fatigued, busted off. I give it a full bevel to cut out the bad spot, weld it up 035 SC. Last twice as long as the brand new one already.

[Dan]

We also need to consider operator skill level. I would never suggest that a newbie try welding this thick of material in short circuit mode. If you set a MM 210 up with c-25 and run it around the settings that i suggested you will end up with a deep penetrating weld bead. You can see the weld burning into the basemetal and then fill the joint back in. There are some large spatter ***** at these settings but this can be handled with anti-spatter spray. Or you could just use the 98/2 and have no spatter.

BTW, for those who dont know, with C-25 Short circuit transfer occurs at about 22 load volts and lower. above 22 load volts you start enter globular transfer. On a MM 210 with C-25 taps 1-5 produce short circuit transfer. Taps 6 & 7 put you into globular transfer with C-25 and spray with 98/2.

[Dan]

Originally posted by Sberry27
Here is one for Dan, I weld a 2 inch bale spear on where it had work hardened and fatigued, busted off. I give it a full bevel to cut out the bad spot, weld it up 035 SC. Last twice as long as the brand new one already.

Sberry is there suppose to be a picture?

[Franz]

Well, the Old Fart is here, and I'm gonna start off with a question. Dan, did you ever run a Miller 225, or were they all out of service when you came along?
I read all the way thru this thread, and I woulda flat out welded the thing with stick and been done before this got to page 2, but that might just be cause I been around a while before MIG machines got so popular.
Dan is right that TIG with a positioner would be the cadillac way to do it, but I welded a lot of these type situations with stick before I owned my first TIG machine.
I ain't sayin this to get anybody's knickers in a knot, but there is way too much emphasis on MIG welding, and entirely too much MIG being done with undersized machines.
I also think we ought to be putting a lot more emphasis on joynt design and preheating before MIG welding especially when a new guy is asking the question.
A lot of the new guys don't even know what question to ask and this thread is an example of that. It started with How do you weld a big shaft to a thin plate, and look where it wound up. If I would have read it and assumed he just wanted to stick a shaft to a quarter inch plate, I would have said run the machine up and favor the shaft, not knowing the actual stresses involved in what the guy is trying to accomplish. Maybe we need to ask some questions before we answer the original posted question.
The people who weld every day or have done it for 10 years know enough tricks to make a weld with any process, and make it so the weld will hold. We also know about every cheat and dirty trick there is to oovercome a bad fitup, but the new guys don't, and if we fail to explain those things, they will have bad results at best, or get hurt at worst. Where Dan or S, or I might see a blowhole as a minor inconvenience, a new guy will chase the hole to Mexico and back before he fills it.
Just a few random thoughts from the Old Fart.

[Sberry]

No I dont have a pic of it. It wouldnt have shown much anyway as I flushed it with a 7 inch sander and you couldnt see the repair when it was finished. I had to think about it,,,, I believe it was 2 or 3 years old when it failed and it has been at least 8 years since the repair and as far as I know still in service.

[big tuck]

hmmmmmmm

i say just use JB WELD

[Scott S]

Dan, I also want to thank you for all of your knowledge that you pass on to us! ( Also all the other regular posters.) Could you explain a bit more on this:
BTW, for those who dont know, with C-25 Short circuit transfer occurs at about 22 load volts and lower. above 22 load volts you start enter globular transfer. On a MM 210 with C-25 taps 1-5 produce short circuit transfer. Taps 6 & 7 put you into globular transfer with C-25 and spray with 98/2.

Details on how to tell the difference (how it looks while welding & finished weld) between those methods. I don't have 98/2 right now, but I am sure I will get it. Thanks Dan!

[Dan]

Franz,

No, I ve never ran a MM 225. I am only 35 and have been welding professional (mainly on food processing equipment) now for 15 years so, there are quite few machines out there that i have never tried out. The MM 225 must have been made several years before I started welding, because I can t even find a manual for it on the Miler site.