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It is best to always use good quality wires, avoiding welding
with rusted wires that could cause welding defects.
Generally, wires may be used within the following current
range: wire Ø x 100 = minimum Amp - wire Ø x 200 = maxi-
mum Amp, e.g.: wire Ø 1.2 = minimum Amp 120/maximum
Amp 240. This with AR/CO2 binary blends and short-circui-
ted transfer.
3) Avoid welding rusted parts, or those with oil or grease
stains.
4) Use torches appropriate for the current being used.
5) Periodically check that the jaws of the earth clamp are not
damaged, and that the welding cables (torch and earth)
show no cuts or burns that could reduce their efficiency.
5.3
WELDING STAINLESS STEEL
Series 300 (austenitic) stainless steels must be welded using
a protection gas with a high Argon content, containing a
small percentage of O2 to stabilize the arc. The most widely
used blend is 98/2% AR/O2.
Do not use CO2 or AR/CO2 blends.
Do not touch the wire with your hands.
The welding materials must be better quality than the base
material, and the welding area must be clean.
5.4
WELDING ALUMINUM
In order to weld aluminum you must use:
1) 100% Argon as the protection gas.
2) A welding wire with a composition suitable for the base
material to be welded.
To weld ALUMAN and ANTICORODAL, use wire with a
Silicon content of 3 to 5%.
To weld PERALUMAN and ERGAL, use wire containing 5%
Magnesium.
3) A torch prepared for welding aluminum.
NOTE: If you only have a torch for steel wires, modify it as
follows:
- Make sure that the cable is not longer than 3 meters (it is
not recommended that you use longer torches).
- Remove the brass liner nut, the gas nozzle, and the con-
tact tip, then remove the liner.
- Insert the Teflon liner for aluminum, making sure that it pro-
trudes from both ends.
- Screw the contact tip back on so that the liner adheres
tightly.
- In the free end of the liner, insert the liner nipples and the
OR gasket, and fasten in place with the nut; do not fasten
too tightly.
- Slide the brass tube onto the liner, and insert the entire
assembly into the adapter (after first removing the iron tube
inside the adapter).
- Cut the liner diagonally so that it is as close as possible to
the wire feeder roller.
4) Use wire feeder rollers suitable for aluminum.
The rollers must not be fully tightened.
5) Use contact tips suitable for aluminum, with the hole cor-
responding to the wire diameter to be used for welding.
6) Use mills and brushing machines specifically designed for
aluminum, and never use them on other materials.
REMEMBER that clean equals quality
The wire coils must be stored in nylon bags containing a
dehumidifying agent.
12
6 WELDING DEFECTS
1- DEFECT-
Porosity (within or outside the bead)
CAUSES
• Electrode defective (rusted surface)
• Missing safety gas due to:
- low gas flow
- flow gauge defective
- regulator frosted due to no preheating of
the CO2 protection gas
- defective solenoid valve
- contact tip clogged with sprays
- gas outlet holes clogged
- air drafts in welding area.
2- DEFECT-
Shrinkage cracks
CAUSES
• Wire or workpiece dirty or rusted.
• Bead too small.
• Bead too concave.
• Bead too deeply penetrated.
3- DEFECT-
Side cuts
CAUSES
• Welding pass done too quickly
• Low current and high arc voltages.
4- DEFECT-
Excessive spraying
CAUSES
• Voltage too high.
• Insufficient inductance.
• No preheating of the CO2 protection gas
7 SYSTEM MAINTENANCE
Safety gas nozzle. This nozzle must be periodically clea-
ned to remove sprayed metal. Replace if distorted or squa-
shed.
Contact tip. Only a good contact between this contact tip
and the wire can ensure a stable arc and optimum current
output; you must therefore observe the following precau-
tions:
A) The contact tip hole must be kept free of grime and oxi-
dation.
B) Sprayed metal sticks more easily after long welding ses-
sions, blocking the wire flow. The tip must therefore be clea-
ned often, and replaced if necessary.
C ) The contact tip must always be firmly screwed onto the
torch body. The thermal cycles to which the torch is subjec-
ted can cause it to loosen, thus heating the torch body and
tip and causing the wire to advance unevenly.
Wire liner. This is an important part that must be checked
often, because the wire may deposit copper dust or tiny sha-
vings. Clean it periodically along with the gas lines, using dry
compressed air.
The liners are subjected to constant wear and tear, and the-
refore must be replaced after a certain amount of time.
Gearmotor group. Periodically clean the set of feeder rol-
lers, to remove any rust or metal residue left by the coils.
You must periodically check the entire wire feeder group:
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