Table of Contents
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S£ S
CRRFTSMRN °
MIG Wire Feed Welder
WELDING
INSTRUCTION
GUIDE
•
INTRODUCTION
.
SAFETY
•
PREPARE
TO WELD
•
KNOW YOUR WELDER
•
ESPANOL
CAUTION:
Read and follow all Safety
Rules
and Operating
Instructions
before
First Use of this Product.
Sears, Roebuck
and Co., Hoffman
Estates,
IL 60179 USA
811-600-000
(June 1998)
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Summary of Contents for Sears MIG Wire Feed Welder
- Page 1 S£ S CRRFTSMRN ° MIG Wire Feed Welder WELDING INSTRUCTION GUIDE • INTRODUCTION SAFETY • PREPARE TO WELD • KNOW YOUR WELDER • ESPANOL CAUTION: Read and follow all Safety Rules and Operating Instructions before First Use of this Product.
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Page 2: Table Of Contents
TABLE OF CONTENTS ..2 Gas Selection For Stainless Steel INTRODUCTION ....Welding ...... 14 SAFETY SUMMARY ..4 Gas Selection For Steel SAFETY INFORMATION ..4 Welding With Silicon SHOCK HAZARDS ....5 Bronze Wire ....14 FLASH HAZARDS ....6 SELECT WELDING FIRE HAZARDS .... -
Page 3: Introduction
Where information is shown that does This Welding Instruction Guide provides basic information about wire feed not necessarily apply to all models or brands of welders, it will be marked as welding. It is to be used together with either optional on some welder models, the User's Guide to provide all of the or does not apply to all models. -
Page 4: Safety Summary
NOTE: Every craftsman respects the tools with which they work. They know that the The following safety alert symbols tools represent years of constantly identify important safety messages in improved designs and developments. this manual. The true craftsman also knows that tools When you see one of the symbols shown are dangerous if misused or abused. -
Page 5: Shock Hazards
TheNational Electrical Code, • Do not touch welder, attempt to turn Occupational Safety a nd Health A ct welder on or off if any part of the body regulations, local i ndustrial codes a nd or clothing is moist or if you are in local i nspection requirements also physical contact with water or moisture. -
Page 6: Flash Hazards
FLASH HAZARDS even when wearing a protective helmet or shield. If welding with a reflective WARNING surface behind you, arc rays can bounce off the surface, then off the filter lens on the inside of your helmet or ARC RAYS CAN INJURE shield, then into your eyes. -
Page 7: Fume Hazards
FUME HAZARDS • Do not weld, cut, or perform other such work on used barrels, drums, tanks, or WARNING other containers that had contained a flammable or toxic substance. The FUMES, GASSES, AND techniques for removing flammable VAPORS CAN CAUSE substances and vapors, to make a DISCOMFORT, ILLNESS,... -
Page 8: Compressed Gasses And Equipment Hazards
eye-irritating gasses. Donot w eld orcut • Do not use a cylinder or its contents for where t hese solvent vapors c an be anything other than its intended use. drawn i ntothe work area orwhere t he Do not use as a support or roller. ultraviolet radiation canpenetrate •... -
Page 9: Additional Safety Information
ADDITIONAL SAFETY • CGA Pamphlet P-I - SAFE HANDLING OF COMPRESSED GASSES IN INFORMATION CYLINDERS - obtainable from the For additional information concerning Compressed Gas Association, 500, 5th welding safety, refer to the following Ave. New York, NY 10038 standards and comply with them as •... -
Page 10: Preparing To Weld
WIRE FEED WELDING weld that needs to be chipped off. Our recommendation for self-shielding, flux- VARIABLES core steel wire is AWS classification number E71T-GS. SELECT THE WIRE NOTE: WITH FLUX-CORE WIRE YOU It is very important t o select a type of wire that is compatible with the metalto WILL BURN THROUGH METALS THINNER THAN 18... - Page 11 Table 1. Aluminum Wire Alloy Selection Chart BASE WIRE WELDING EASE WELD DUCTILITY USE IN TEMPS COLOR MATCH LOW CORROSION METAL ALLOY & CRACK STRENGTH OVER 150 AFTER WHEN IMMERSED ALLOY RESISTANCE DEGREES ANODIZING IN WATER 7005 7021 7039 5356 GOOD GOOD GOOD...
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Page 12: Stainless Steel Wire Selection
Stainless Steel Wire Selection steel welding wire be bought in When weldingstainlesssteel, the alloyof spool sizes that will be consumed in six months or less. In the early the weldingwire mustbe the same as the alloyof the basemetal. As with stages of aging, the copper coating will begin oxidizing. -
Page 13: Selecting The Wire Diameter
recommendations supplied in Table 2 are steel wire is quite expensive, it is still a good practice to follow the for typical applications only. storage recommendations. Table 2. Wire Diameter Amperage SILICON-BRONZE WIRE - spools Ranges (Typical) should be selected based on the same guidelines as for copper- METAL WIRE... -
Page 14: Gas Selection For Aluminum Gas Welding
mixture o f75% Argon and 25% Carbon greatly reduced penetration. The Dioxide, though 1 00% Carbon D ioxide is only remedy is to replace the also acceptable. DONOT USE Argon cylinder. gasconcentrations higher than75% on INSUFFICIENT SHIELDING GAS steel. T heresult willbeextremely poor COVERAGE - This problem can be penetration, porosity, andbrittleness of... -
Page 15: Setting Up The Work Piece
extinguisher andbucket ofsand from the weld joint area and from available. the site where the workpiece clamp will be connected. Toproperly prepare forwelding, itis To determine if the aluminum you intend necessary to: to weld is anodized, simply touch the two 1. - Page 16 45" PLATE BUTT WELD JOINTS PLATE 37.5" SINGLE V JOINT SINGLE BEVEL JOINT 60" DOUBLE BEVEL JOINT DOUBLE V JOINT 3/32" TO 1/8" -_/_ .10,. TO 1/8"\ / VEE JO,NT _11_ CLOSED JOINT SHOULDER EDaE _80" 1/4" OR MORE "_ _/80",.._/ OPEN JOINT...
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Page 17: Workpiece Clamp Connection
WORKPIECE C LAMP CONNECTION It is best to connect the workpiece clamp ARC RAYS CAN INJURE WARNING directlyto the work pieceand as close to EYES AND BURN SKIN! To the weld as possible. If it is impractical reduce the risk of injury from to connectthe workpiececlamp directly arc rays, never strike a welding arc until to the work piece,connectitto the metal... - Page 18 wide preferred sounding range. setting. It is possible, therefore, The range could span as much to use the wire speed control to as 60 ° on the WIRE SPEED slightly increase or decrease control. It is important to know heat and penetration by that the heat of the arc and selecting higher or lower wire penetration into the base metal...
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Page 19: Get To Know Your Welder
If angle A is decreased, penetration LEARNING TO WELD will decrease also. Whether you have welded before or not, it is important that you become familiar with your new welder, its controls, and the results achieved at different settings. We strongly recommend that you practice with your new welder on scrap metal trying different heat settings, base metal thicknesses, and welding positions... -
Page 20: Distance From The Work Piece
On a fillet weld joint, the nozzle is WELDING TECHNIQUES generally positioned in such a manner so as to split the angle between the MOVING THE GUN horizontal and vertical members of the Gun travel refers to the movement of the weld joint. -
Page 21: Types Of Weld Beads
There are two basic types of weld beads, will help to overcome this the stringer bead and the weave bead. problem. ALUMINUM WELDING can The STRINGER BEAD (Figure 7) be done using either is formed by traveling with the gun in a straight line while keeping the direction of gun travel, but wire and nozzle centered over the... -
Page 22: Welding Positions
WELDING POSITIONS There are four basicweldingpositions: fiat, horizontal, v ertical,and overhead. The FLAT POSITION (Figure9) is the easiestof thewelding positions and is probably theone you have been usingthusfar. It isbestif you canweld in thefiatposition ifat all possible as goodresultsare easier to achieve. -
Page 23: Multiple Pass Welding
The OVERHEAD POSITION The illustrations in Figure 13 show the sequence for laying multiple (Figure 12) is the most difficult pass beads into a single V butt joint. welding position because gravity is pulling at the weld puddle trying to NOTE: WHEN USING SELF- make it drip off the work piece. -
Page 24: Special Welding Methods
SPECIAL WELDING Always select the HIGH heat setting with the burn-through METHODS method and tune-in the wire speed prior to making a spot weld. SPOT WELDING The PUNCH AND FILL METHOD The purpose of a spot weld is to join produces a weld with the most pieces of metal together with a spot of weld instead of a continuous weld bead. - Page 25 Make practice spot welds on scrap metal, varying the length of time you hold the trigger, until a desired spot weld is made. Make spot welds on the actual work piece at desired locations.
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