TIG Welding X-Ray Hack! TIG Technique For Pipe Welding!
Summary
TLDRIn this Extreme Tech channel video, the host demonstrates how to weld a four-inch diameter pipe using a back purge technique for X-ray quality results. He shares tips on purging, using a heavy-duty torch, and maintaining the right temperature and amperage for the welding process. The video covers the importance of clean materials, proper beveling, and gap control. The host also explains the lay wire technique, back fit, and the use of different rod sizes for various stages of the weld, emphasizing the significance of each pass for a flawless finish. The video concludes with advice on post-weld cleaning and the importance of PMI, PT, and X-ray testing for quality assurance.
Takeaways
- 🔥 The video demonstrates welding a 4-inch x-ray quality pipe using a back purge technique.
- 🛠️ Welding is performed on 316L stainless steel, which requires specific techniques and equipment.
- 💡 The welder shares tips on purging the pipe with argon gas for 10-15 minutes at 30 liters per minute for optimal results.
- ⚙️ A heavy-duty torch from the 'Heavy Heated' brand is recommended for its ability to run hot without overheating.
- 🌡️ The video emphasizes the importance of preheating the pipe and controlling the heat input during welding.
- 🧰 The 'lay wire technique' is used for the initial pass, which involves keeping the wire inside and stretching the weld puddle.
- ✂️ It's advised to weld between tacks first and then cut and grind them out to improve efficiency and reduce oxygen contamination.
- 🔩 The welder uses a cup size 8/18/38 tungsten and an air-cooled torch for the process.
- 🛑 The video highlights the significance of pausing before tie-ins to ensure a smooth transition in the weld.
- 🏗️ For the hot pass, a 332 rod is used with 120-130 amps, focusing on stretching and controlling the weld puddle.
- 📈 The final cap pass involves three layers, with each pass overlapping the previous one by 50% to ensure a smooth and even finish.
Q & A
What is the main focus of the video?
-The main focus of the video is to demonstrate the process of welding a four-inch pipe using a back purge technique, with an emphasis on X-ray quality welds.
What is the significance of the 'magic number 30' mentioned in the script?
-The 'magic number 30' refers to the ideal flow rate for the purge gas in liters per minute, which is recommended for welding pipes of various diameters for optimal purge effectiveness.
What type of torch is recommended for the welding process described?
-The recommended torch for the welding process is a heavy-duty, air-cooled torch from the Heavy Heter brand, which can run hot without overheating like regular water-cooled torches.
What is the purpose of purging before welding?
-Purging before welding is done to remove oxygen and other contaminants from the weld area to prevent oxidation and porosity, ensuring a high-quality weld.
Why is it advised to weld between tacks before cutting them?
-Welding between tacks before cutting them is advised to increase welding efficiency by reducing the need to purge oxygen introduced by grinding, thus saving time and maintaining weld quality.
What is the 'lay wire technique' mentioned in the script?
-The 'lay wire technique' is a welding method where the welder keeps the wire inside the weld pool and stretches the pool side to side, which helps in controlling the weld and preventing gaps.
Why is it important to maintain a clean pipe surface before welding?
-Maintaining a clean pipe surface is crucial for achieving a high-quality weld as contaminants can lead to defects such as porosity and inclusions, which can compromise the weld's integrity.
What is the recommended amperage range for the hot pass in this welding process?
-The recommended amperage range for the hot pass in this welding process is between 120 to 130 amps, which is suitable for stretching and controlling the weld puddle effectively.
How does the welder ensure a smooth start and stop in the weld?
-The welder ensures a smooth start and stop by preheating the area, melting the rod, and using a technique that involves dipping the rod and feeding it side to side, which helps in creating a smooth and even weld.
What is the significance of the third pass in the cap of the weld?
-The third pass in the cap of the weld is significant as it covers any imperfections from the previous passes, maintains a straight edge, and demonstrates the welder's control over the arc and puddle, resulting in a visually appealing and high-quality weld.
Outlines
🔥 Welding a 4-inch X-ray Quality Pipe
The speaker introduces the video by welcoming viewers to the Extreme Tech channel and stating the project for the day: welding a 4-inch diameter pipe to X-ray quality standards. They emphasize the importance of using a 316L stainless steel material and discuss the use of 3-inch and 4-inch pipes with 3 mil and 4 mil thicknesses. The video focuses on welding techniques, including proper purging for 10-15 minutes at 30 liters per minute, which is described as a 'magic number' for effective purging. The speaker also thanks Nathaniel Koza for providing a high-quality torch and discusses the use of an ER70S-6 rod with a 400 amp welding machine. They detail the use of an air-cooled torch with a cup size 8/18 and a 3/32 tungsten, highlighting its effectiveness for welding. The video then transitions into demonstrating the 'lay wire' technique for welding, starting from the bottom and working upwards, with advice on preventing gaps and maintaining a clear view of the weld area.
🛠️ Welding Techniques and Tips
This paragraph delves deeper into the welding process, emphasizing the importance of preheating and maintaining a clean, smooth start and stop to the welds. The speaker recommends purging for 5-10 minutes depending on the spool length and pipe diameter. They discuss the technique of starting the weld from the inside and moving outward, using a 'dipping' technique to feed the rod side to side. The speaker shares their preference for keeping the rod inside the weld until around the 11 o'clock position before switching to the outside. They also mention the use of 109 or 105 amps for the process, highlighting the importance of visibility and control over the edges of the weld. The paragraph concludes with advice on the hot pass, using a 332 rod at 120-130 amps, and the importance of a clean, wide bevel for effective puddle control and weld quality.
🌐 Advanced Welding Passes and Cap Techniques
The speaker continues with advanced welding techniques, focusing on the fill pass using a 1/8 rod at 150 amps. They discuss the importance of using a buffing wheel to clean each pass, avoiding the need for a grinder except for stop starts. The video demonstrates the process of closing the field to flash, switching to two beads, and overlapping them by 50% to ensure a smooth, hole-free finish. The speaker then moves on to the cap pass, emphasizing the need for equal steps and maintaining a straight edge. They describe a three-pass cap technique, with the third pass being crucial for covering any missteps from the previous passes and ensuring a neat, professional-looking weld. The paragraph concludes with a reminder to perform a PMI test, PT test, and X-ray test to ensure the weld's quality.
👋 Wrapping Up the Welding Tutorial
In the final paragraph, the speaker wraps up the tutorial by summarizing the key steps and techniques discussed throughout the video. They reiterate the importance of welding between tags, cutting the tacks last, and purging for 10-15 minutes depending on the pipe's diameter. The speaker thanks the viewers for watching and hints at future videos, encouraging them to apply the techniques and tips shared in the tutorial to their own welding projects.
Mindmap
Keywords
💡X-ray
💡Purge
💡Tungsten
💡ER rod
💡Hot pass
💡Bevel
💡Amps
💡Cap pass
💡Feather edge
💡PMI
Highlights
Introduction to welding a four-inch diameter pipe using a back purge technique for X-ray quality welds.
Explanation of the importance of purge time and the 'magic number 30' for optimal purge effectiveness.
Demonstration of using a heavy-duty torch for welding and its benefits over traditional water-cooled torches.
Tips on selecting the appropriate tungsten size and torch for air-cooled welding applications.
Technique of using the 'lay wire' method for welding, ensuring a clean and controlled weld pool.
Advice on welding in sections to prevent gaps and ensuring a tight weld without excessive material removal.
Emphasis on the importance of preheating and maintaining a consistent heat input for quality welds.
The back fit technique for welding small diameter pipes, explaining the process from the top down.
Highlighting the significance of a good purge to prevent discoloration and ensure a quality root pass.
Technique of grinding stop starts for a smooth and clean weld transition, minimizing the need for purging after grinding.
The dipping technique for the hot pass, explaining how to stretch and control the weld puddle effectively.
Importance of keeping the rod inside the weld puddle and the correct angle for optimal puddle control.
Explanation of the fill pass technique using a single pass side to side for a clean and efficient fill.
Switching to a larger rod and higher amperage for the final cap passes to ensure a smooth and robust finish.
The process of overlapping cap passes to create a smooth and even final weld surface without holes.
Final thoughts on the importance of maintaining a straight edge and consistent width for a professional-looking weld.
Conclusion and reminder of the importance of cleanliness, gap, and bevel in achieving X-ray quality welds.
Transcripts
foreign
and welcome to the extreme Tech channel so for today's video guys uh I'm going to
work on a four inch x-rays to Strong uh Yuri a great pipe it's going to be a back perch x-ray
quality I'm going to show you a couple tricks and tips uh how to do it uh the best practice
a little bit advice maybe you can apply this to any urea grade is pretty much as a 316 as
you can notice here I got three inch and a four inch uh three mil and a four mil Gap
it's pretty much loose one eight uh this is gonna do we got four attacks three tags in this
case I'm just gonna leave it to purge couple minutes 10 to 15 minutes uh that's uh ideally
and with the purge I go around 30 uh latest RPM liters per minute this is Magic Number 30 Works
uh great even for bigger diameter pipe usually my rule thumb is uh 10 inch and above I usually
insert like three hoses of purge I like The Purge for like for 20 minutes half an hour it all
depends and this is a torch uh I got for my body shout out to Nathaniel Koza from Louisiana thanks
buddy I appreciate it this is a really amazing torch heavy heater brand uh works really great
uh this torch uh I was looking for a long time you can really really run hot and it's
not gonna get really hot like those regular 150 amp storage or 200 amps uh no water cool torch
so once again thanks Nathaniel but I appreciate it uh as you can notice 25 22 too is a ER rod
for uh for tinga it's a urea grid and a big blue for 400 welding machine so for my torch
I'm using a cup size 8 1 8 38 tungsten this is a air cooled torch it's really amazing
if you guys can check out their brand uh on a online heavy heater if you got opportunity
yeah that torch is going to make your life easier so the little tips and tricks I'm
going to show you here on this pipe I'm Gonna Roll in between tax I'm gonna start [Music]
start on the bottom first this is just showing you pretty much it's going to be a lay wire technique
until I hit the top usually I what I do I usually a section part on the top I always
go like deep side to side just to prevent you know grapes and it doesn't take down too much
and this is Lay wire technique just keep the wire inside and stretch that bottle burn those edges
always go with the feather edge on my prep I just kind of have a nice and clear picture
what's going on you can put a little bit of land it all depends from the habit and what you prefer
okay as I said I did start on the bottom first and um and I did in between three and twelve o'clock
so the first the first idea is uh just weld in between text don't
cut attacks yet uh well first in uh in between and once uh you're done
then we're gonna switch to grind them out uh the good idea to do that is uh
it makes you weld faster yeah you don't insert any air inside you by using a grinder
pretty much every time you cut attack you gotta wait a little bit to purge all that oxygen you
put from your grinder and this way it's uh just more efficient and a little less time consuming
so the same idea on the bottom uh preheat and I'm gonna fit from the top this is a
back fit here on the bottom pretty much uh on a small diameter is always uh fit from the top
or like from 10 o'clock it depends from which side you are like two three o'clock one side
or nine to ten o'clock on the other side feet from the top it's like a back fit technique
give that give that rod in a puddle stretch that puddle side to side
at the good I like a heavier wool fits your cup inside uh perfect you
can uh you can wiggle you can walk the cup inside the root
or you can you can freehand whatever it's easier for you okay now do all those uh was
in the in between texts are done now I'm gonna cut attacks out this is the root looks nice looks good
a good Purge know any discoloration on the root uh that means that number
30 that magic number for Purge uh works good and I highly recommend it
temperature heat input okay now uh once you've got all those stacks grind stop starts so you got
nice uh smoothie feather out all those stop starts so you can have nice start and stop
and let it Purge for uh five to ten minutes it depends from the length of your spool or diameter
and the same idea preheat I must start melting at a rod and try to keep that Rod usually what
I do I always uh try to keep my rod inside all the way up to the let's say around the 11 o'clock then
I switched from the outside and started feeding road side to side just like a dipping technique
the amps I was using here as uh shown on beginning it was a 109 or 105 amps you can go lower
I just like the feather edges I I can see my edges they are just uh
they they are burning you can wash those edges and you can see clearly as I said on
on the top I switch to dipping technique and for the tie-in I like to pause right
before the tie-in pause a little bit and Rod as needed and just go over maybe half inch or so
and that's it pretty much so in this case uh it's uh they do empty on the root on the root
path from the outside so I just uh grab a grinder especially if you got a scratch start then you
know just in case if you don't uh insert any any tip of your tungsten and stuff like that
later in my shown on an X-ray you can just run a run a grinder just a little bit on a Surface not
a big deal or even buffing wheel works good too okay so for the hot pass uh 120 130 amps
this is 332 rod
this is the best part of the welding hot pass usually especially when you
got nice and wide bevel heavy wall then you can really stretch and play with that puddle
it's pretty much simpler guys okay they rode the 10 15 degrees you
know in that puddle inclination of your tungsten is important as well
you know that's uh that's how you stretch puddle you point that tip
of your tungsten that's what melts the rod
and then you stretch that puddle new washing sides side to side motion
you don't want to lift too much up and then just burns your Rod you know and then every time you
lose that connection from your puddle then you got to reconnect and all depends from the material
then you get the any impurities and uh stuff like that like in any other any other pipe that's in a
code guys uh the pipe should be clean clean clean that's the one of the most important thing beside
the Gap and uh and the bevel okay same thing for the for the fill I'm just gonna go one pass
side to side I'll just run one pass here on the on this pool um as much as I can I'm gonna do my fill
with a with one well one pass fill side to side now I switched to trade uh to 1 8 rod 150 amps
and I I got lots of questions about the amps uh what I shouldn't what you
guys should do on a hot pass it all depends how much you can handle guys
um hot passes it doesn't mean that you got to go really hot uh the hot pass is just a term
used for 70 18 after after six to ten root uh to burn all those uh slag and uh that leftovers from
six to ten by the hot pass it is recommended to go a little bit harder you know just um if
you got like some little pin holes in this and that you know especially it all depends from the
material guys but as I said go how much you can handle you know have to go 120 or 130 or 150.
as long as it looks nice nice and smooth proper steps yeah it should be fine okay this is the
first pass to fail he's gonna ride a buffing wheel now I'm going to do third pass same thing
one bead side aside I'll just try to go walk with uh one bit to try
to fail and later I'm gonna switch to the probably cup size 10. or even 12.
so you can have a wider bead as well
but as long as you have a nice and clean uh base for each pass
and a good heat and it's just gonna melt your rod and just leave it pretty much only using buffing
wheel to clean each pass no use of grinder no need it except maybe for the for the for the stops
the with this material like uh just uh the way of
guys show nice and colors it's all uh you can see that's a little bit hot
but it's inside the weld Zone it's not the outside on a pipe which is good
okay now almost uh close the field to flash now I'm gonna switch on the two two beads
do well beads on a one on each side overlapping fifty percent of each
the idea is just to cover and make a nice and smooth feel to flash without any
holes in the middle
this filter flash just gonna go over up to that edge
try to make a nice smooth
and try to overlap with that first bait you did
okay that's it pretty much uh failed to flush I might run actually one in the middle
and I did a round one in the middle and now this is the first pass of cap I'll go with a
three pass cap on this pipe
like always uh first first pass uh try to have equal equal steps on the side try to
maintain that uh to have a straight edge take keep an eye on the the same vid of your steps
that's it for the first pass
now I'm gonna go with the second pass
I'm overlapping here uh 50 of my first pass
and uh going on the other side leaving enough room for the third pass you can always use a
calculation how many bits you're gonna put on a cap depends how wide is your uh bevel
but like for the bigger I know guys some guys go like uh to pass cap a little bit wider uh
steps I just like have nice and tight everything I like I like having uh tight steps uh on a my cap
and three pass it should be good enough for this diameter okay this is a second pass done
all right now we're going to do the third pass and the last the final pass
as I said always and I'm gonna repeat always uh this is the cherry on the top
the third pass is a most crucial one it's pretty much important same as the first one
it covers that straight edge on a pipe but uh and second pass covers all uh you know if
you got any misstep on the first pass the third pass covers the second pass by the
third pass try to maintain the same width on the both sides try to have that straight edge
and this is what makes you weld looks really nice at the end when it's done that's uh that's
what shows your uh how focused you are with your welding and your control Arc and puddle control
and that's it pretty much uh this is a three-pass cap
now the later is uh PMI PMI test ft test and uh X-ray test as so guys as I said guys uh
try to try to follow try to follow try try to implement those steps you know try to weld in
between tags and then cut the text last and then you got only one time use grinder and
finish all tags uh grind all those top starts and let it Purge 10-15 minutes
depends from diameter and that's it thanks for watching guys and see in the next one take care
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