flux core weld test

[tiginator]

I am taking a flux core test and I havn't welded flux core in about 3 years. The process is duel shield with NR 211. The volt range is 22-27 volts the wire size is .054 ( I believe. I know its .05 something ). The test consists of 1/2" x 8" plate in the 2g 3g and 4g position. It is an open root test, with 6010, for the stringer. this part I have no problem with. I'm just a little rusty on the flux core, since it is going to be x rayed. What voltage, do I run stringers or a weave that sort of stuff. If anyone has any advice it would be greatly appreciated.

[Sandy]

I thought NR-211 was a self shielded wire, a E71T-11?

[galencwi]

I am taking a flux core test and I havn't welded flux core in about 3 years. The process is duel shield with NR 211. The volt range is 22-27 volts the wire size is .054 ( I believe. I know its .05 something ). The test consists of 1/2" x 8" plate in the 2g 3g and 4g position. It is an open root test, with 6010, for the stringer. this part I have no problem with. I'm just a little rusty on the flux core, since it is going to be x rayed. What voltage, do I run stringers or a weave that sort of stuff. If anyone has any advice it would be greatly appreciated.

do you know what the root opening is. ?

More than likely your running 3 tests it sounds like .052 wire dual shield has a flux core and is usualy ran with Co2 or 75/25 depending on the application

211 is a self sheilding wire that requires no shielding gas.

I can give you pointers on .052 dual shieild.
Older machines run different from one to the next even tho they are the same brand.
for the most part you will want to run fairly hot I typically am running at 27-28 v and wire speed between 275 to 300+. Try not to go much higher than that you can really get a big weld going and it wont fill the test cupon evenly. on the new lincolns (only time I have to turn it up higher than that is I may be working 400+ ft away from my machine. Have to compensate for line voltage drop)

I set my Co2 about 40-45

In every position get comfortable. brace part of your body so your hands are free and steady.

2G open root Start on the upper bevel let the puddle build and flow down onto the lower plate. Then start your pass. Drag your nozzle do not push. That way you get a better burn in and less chance of trapping slag in your weld.
Do not try to fill your plate in 1 pass!! After that run stringers stacked from bottom to top. Work with gravity not against it. To easy to get a cold lap or pocket of slag that will definately show on x-ray. Before you get to your cover 2-3-4G LET YOUR PLATE COOL! By the time you get to the cover the plates super hot and very easy for the wire to burn in or thru.

(For 3G and 4G it is very important not to rush Stay right in your puddle.If you try to rush the weld on 3G or 4G you will lose your sheilding gas and you can burn thru or have your weld drop out. Now your screwed!!! Where I work you cannot take your plate down until its finished and theres no grinding allowed.)

Anyway for your first pass 3G and 4G you want to start out on one flange and let the puddle build up across the root a little then begin your weave. NOT a huge weave because you can end up with lack of fusion showing on x-ray. The key with both is to not put your heat in the root opening. weave and hold weave and hold. Once you practice it you can see and know if your holding long enough. The weld should be washed up on the sides.of the bevel. If your weaving to fast you'll have undercut. Another place for slag to get trapped.
Again I always run stringers overlapping at least 50%. When your less than 1/8th" from the face you can start your cover. Make sure you over lap them
VERY important is STAY IN THE PUDDLE.

For 4G a slight adjustment is needed. I will run a little hotter like 29 and wire speed at 275. The reason is it burns in really. Try it once both ways you'll have almost no splatter trying to fill your nozzle when you turn up the heat.

Most of my picks are from Navy test certifications so there are even strickter guidelines we had to follow. But the weld process is the same.

[tiginator]

I hope I didn't get bad info. I heard it was nr 211 and it is definately duel shied. Is nr 211 never run with a shielding gas? I know it is self shielding. does that mean that they don't run it duel shield?

[galencwi]

I forgot to mention if your are welding flux core with a backing strip. Use the entire build up and run off tab. Youll get a better tie in for your root. Most inspectors will check your root pass before you can fill it up. and if there is not 100% tie in then its a fail!

Overhead on 1/2" and 5/8" plate it will get really smokey when you start your root pass. Position yourself so you can see your puddle clearly end to end.
Also on the over head, if you dont have enough build up on the run off tab. You can loose your shielding gas causing the weld to fall out. Right on the end. Usually falls right in your nozzle! or on your pant legs catching on fire. lol :angry::realmad: Then your doing a dance in the test booth :cool2:

[galencwi]

Yeah those are 2 different welding processes. You prob should call someone so you know what your testing on.

Dual shield = just like it sounds. Inner and outer shield (Co2) cover gas.

NR 211 is a self shielded wire. Most wires you have questions with you can look it up on lincolns or hobarts website.

This is for 211
http://www.lincolnelectric.com/en-us/Consumables/Pages/product.aspx?product=Products_Consumable_Flux-CoredWires-Self-Shielded-Innershield-InnershieldNR-211-MP(LincolnElectric)

[galencwi]

ok then 211 self shieldng wire. no gas needed/no nozzle needed take it off
wear leathers or sleeves if your running this.
do you know what they weld on?

the machine gets set in reverse polarity.
Your still going to be pulling not pushing. But this is a fast freeze so oscillation is not the way to go. start oscillating and slag gets trapped in the weld.
you want to run all stringers.

you have to play around with the voltage it depends on what your power source is like, newer one will have really steady power if you run a bead and the slag starts peeling up then thats perfect.

[tiginator]

ok so I did some research and you were right. The wire is not NR 211, it is ER71T-1. They had me run 211 the first day but we got the right stuff now. I used .045 for practice since thats what they had. I ran my 2g and 4g at 25.1 volts and wire speed at 275. the vertical I turned down to 23.1 and same wire speed . I ran stringers for all three and I did pretty good. I am concerned about my hot pass on the test because it is open root and the first pass is 6010. I'm afraid the hot pass will burn through. should I stay on the bevel and away from the center.

[galencwi]

ok so I did some research and you were right. The wire is not NR 211, it is ER71T-1. They had me run 211 the first day but we got the right stuff now. I used .045 for practice since thats what they had. I ran my 2g and 4g at 25.1 volts and wire speed at 275. the vertical I turned down to 23.1 and same wire speed . I ran stringers for all three and I did pretty good. I am concerned about my hot pass on the test because it is open root and the first pass is 6010. I'm afraid the hot pass will burn through. should I stay on the bevel and away from the center.

sounds like your pretty comforfortable w the wire. :cool2: thats great
how good is your root? if your roots good and your flow is steady then you really can turn up the heat the only one i would be careful on is the 3G i would weave a little on the hot pass. (It doesnt hurt to weave a little on any hot pass and make sure you get a good tie in.)
By the time you get to the top of the test plate it can be easy to burn thru if your moving a lil slow.
in flat .045 ill crank it up to 28v and 300

[Fat Bastard]

I thought NR-211 was a self shielded wire, a E71T-11?

It is. :waving:

[galencwi]

Love your story on government irony FatBastard!

[tiginator]

Well I just got back from the job and I did pass the gate test. I start back on monday. Thanks for all the info. It helped alot.