Frequently Asked Questions

Technical:

1. What is the benefit of load banking a gas/diesel welder?
   
2. What does the term "wet-stacking" mean?
   
3. When I turn on my 110 volt wire welder, the fan runs, but it will not feed.
   
4. When I turn on my 220 volt wire welder, it takes a long time for the fan to come up to speed. Is the fan faulty?
   
5. What tungsten do I use to weld aluminum?
   
6. What is meant by "straight" and "reverse" polarity?
   
7. What do the numbers on welding electrode mean?
   
8. What causes porosity when stick (SMAW) welding?
   
9. What are some common causes of porosity in the GMAW weld deposit?
   
10. How do I know what shade lens to use on my helmet?
    
11. Why does my machine shut off after only 5 or 10 minutes of welding?
    
12. What is duty cycle?
    

Gas Related:

1. What pressure should I run my CO2 or CO2/Argon shielding gas at?
   
2. What welding applications are best for argon/CO2 shielding gas as opposed to straight CO2?
   
3. My new CO2 cylinder is only registering 500 lbs. Is there a leak?
   
4. Who are your stocking dealers for gases and / or hardgoods?
   

General:

1. What is the difference between ferrous and nonferrous metals?
   

Q: What is the benefit of load banking a gas/diesel welder?

A: The purpose of load banking a welder is to seat the rings in the piston bore. The engine is run at a rated load for a specified period of time to "wear in" the new rings so they form a better seal with the piston wall. The rings seal the combustion chamber so it can compress the air/fuel mixture, and also the rings provide an oil seal within the chamber. Without proper seating of the rings, the compression will be low and the engine will burn oil.Load banking gives a "running start" of sorts to the break-in process. The average time for an engine to be completely "broken in" varies, but averages between 50 and 100 hours. What occurs with the engine during the initial run hours has a significant impact on future engine performance.

Q: What does the term "wet-stacking" mean?

A: Wet stacking occurs in a diesel engine when the engine is run at too light of a load during the run-in (also known as load banking). This causes unburnt fuel and oil to collect in the exhaust stack. The exhaust stack will be coated with a black, sticky, tar-like substance. If you run a new unit at light loads and/or idle for too long, the rings will not seat properly. If it is a diesel, wet stacking may occur. Both of these conditions will cause poor engine life and performance.

Q: When I turn on my 110 volt wire welder, the fan runs, but it will not feed.

A: 1. Make sure the wire speed knob is not set at "zero".2. Make sure the heat range knob clicks into the desired setting. If the knob is on "purge" or between settings, it will not feed.

Q: When I turn on my 220 volt wire welder, it takes a long time for the fan to come up to speed. Is the fan faulty?

A: Not necessarily. Check your incoming power; it may only be 208. Consult your owner's manual to see if your welder can be set to run on 208.

Q: What tungsten do I use to weld aluminum?

A: When welding aluminum, you should use pure tungsten. When welding steel or stainless, use 2%.

Q: What is meant by "straight" and "reverse" polarity?

A: Straight Polarity means the electrode is negative, and the work is positive. Reverse Polarity means the electrode is positive and the work is negative.

Q: What do the numbers on welding electrode mean?

A: Arc welding electrodes are coded by the American Welding Society (AWS). Each AWS number gives specific information about the electrode.

Classification of mild and low alloy steel electrodes are based on an "E" prefix and a four or five digit number. The first two numbers (or three if it is a five digit number) indicate the tensile strength in thousands of pounds per square inch (psi). The next digit indicates the welding position in which the electrode is capable of making a satisfactory weld (1= All position; 2= Flat or horizontal). The last digit indicates the type of current to be used (AC, DC-, OR DC+) and the type of coating on the electrode (Organic, Rutile, Low Hydrogen, Mineral Iron Powder, or Low Hydrogen Iron Powder).

For Example: E7018

• E - indicates arc welding electrode
  
• 70 - indicates a minimum of 70,000 psi tensile strength
  
• 1 - indicates the electrode can be used in all positions
  
• 8 - indicates the electrode is coated with a low hydrogen, iron powder and can be ran either in AC or DC+ current.

Q: What causes porosity when stick (SMAW) welding?

A: One of the main causes is very oily or very rusty metal. It can also be caused by a bad electrode.

Q: What are some common causes of porosity in the GMAW weld deposit?

A: Probable causes for porosity are: a dirty base metal, wind, improper gas shielding, incorrect filler wire, and too high voltage. Remedies to try: clean base metal, check cylinder valve (tighten fittings, check flow rate, proper gas), use proper filler wire, and adjust your power source.

Q: What is the difference between ferrous and nonferrous metals?

A: Ferrous refers to a metal that contains primarily iron. Steel, stainless steel, and cast iron are examples of ferrous metals. Nonferrous therefore means the metal contains no iron. Aluminum, copper, bronze, brass and tin are examples of nonferrous metals.

Q: How do I know what shade lens to use on my helmet?

A: A general rule of thumb is:

• Shade 3, 4, or 5 for gas welding or cutting or gouging
  
• Shade 6 or 7 for plasma arc cutting
  
• Shade 8 and above for stick, TIG, or MIG

Q: Why does my machine shut off after only 5 or 10 minutes of welding?

A: You are probably experiencing the effects of "duty cycle" (see below). Many machines are designed to shut off automatically after a period of continuous operation. This is to protect the machine from over heating.

Q: What is duty cycle?

A: Duty cycle is the percentage of time in a ten-minute period that a welding machine may be operated continuously at manufacturers rated output, without fear of overheating or damaging its components. For example, 30% duty cycle means you can weld for three minutes in a ten-minute period.

Q: What pressure should I run my CO2 or CO2/Argon shielding gas at?

A: In most welding applications, 12 to18 psi is recommended, depending on the air movement in the welding area.

Q: What welding applications are best for argon/CO2 shielding gas as opposed to straight CO2?

A: Most of the better quality wire welding machines will weld very well using straight CO2 as the shielding gas. Straight Co2 is recommended for general fabrication or repair work that will not require much clean up.If the weld is decorative, or body shop type work, it is recommended to use the Argon/CO2 mix. There will be a smoother bead, and very little spatter. The mixture will always leave a more aesthetically pleasing weld.

Q: My new CO2 cylinder is only registering 500 lbs. Is there a leak?

A: The cylinder is full at 800 lbs, however this depends on the temperature of the cylinder. If the cylinder is cold, the pressure drops. As the cylinder warms up, the pressure will increase again, to read the pressure of a full cylinder.

Q: Who are your stocking dealers for gases and / or hardgoods?

A: