Want to learn how to fusion weld? Learning how to do it isn't hard. Once you have mastered the basics of MIG welding, you will never forget it.
First, when you decide how to fusion weld, whether you want to use gas-free flux-cored wire or solid wire with shielding gas. If you are welding at home, the best choice is likely to be gas-free mig wire. If you choose to use solid MIG wire, you will have to pay the extra cost of the gas in the bottle as well as the cost of renting the bottle itself. In Australia, this is what we have to do. For example, if you are lucky and you live in the US, I believe you can actually buy your gas bottle outright so you don't have to keep paying the monthly rent.
When you fusion weld, you must use the correct size wire for the correct size contacts. So, for example, if the wire diameter is 0.9mm, you will need to use a contact marked 0.9mm. The exception to this rule is if you are using flux cored wire or aluminum wire. In this case, you will need to use the next larger contact size, which in this case is 1.0mm.
In addition, you need to make sure that the drive roll or feed roll is marked with the same size wire. There are three different types of recesses available for the feed rollers. The available profiles are "V-groove", "U-groove" and "knurled groove". Each of them is designed for a specific type of wire.
For solid wire, use the V-groove for solid wire, the U-groove for aluminum, and the knurled groove for flux-cored wire. If you use the wrong roller, you will experience wire feeding problems, which can lead to poor soldering.
Next, you need to attach the wire to the machine. The trick to the tensioning mechanism is to make sure you don't over-tighten it. If you make it too tight, it will flatten the wire out of shape. The copper coating will start to peel off the solid wire and the gas-free and aluminum wire will become difficult to pass through the torch.
Now make sure you are wearing the proper safety gear, such as boots, coveralls, gloves and a welding cap.
Attach a ground clamp to your work and adjust the wire feed speed and voltage settings according to the manufacturer's guidelines. Today, many MIG welders have a chart inside that shows parameters such as wire feed speed.
For example, if your machine doesn't have this because it's too old, start doing some practice welds on some scrap metal. Once you have a good setup, then you can move on to the work you want to do.
After you finish welding, you may need to touch up all the welds with an angle grinder, depending on how good you are. I like to use flap discs because the metal surfaces blend well and are smooth.
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