Bad Sheet Metal Weld

When welding sheet metal the main thing to look out is to prevent warping and burn through.

Bad sheet metal weld.

Take the time for proper fit up proper tight part fit up is especially important when welding thin materials. Not only do they look horrible but they make the metal structurally weak and less safe. While sheet metal is primarily a tig welding job there are times when it s handy to have an available mig welder to fuse sheet metal. It requires a lot of experience patience and skill to get the desired results.

Underside of weld has insufficient penetration excessive globules of metal over sized weld undersized welds undercut overlap incomplete fusion porosity and or cracking. They can also cause costly future repairs if the rust spreads to vital components and damages them. This is due to many factors that came into play. Even professional welders can create excessive heat affected zones and burn through while welding sheet metal.

Lap welds because they cannot flex like the sheet metal around them will eventually show visible creases. The hobart handler 140 mig is the best affordable mig welder for sheet metal. Sheet metal is a lot thinner than other materials that one needs to weld so a completely different approach is needed. Also clean the metals before even starting to avoid the build up of oxide layers.

A 100 argon shielding gas is the most common in mig welding aluminum sheet metal. Mig welding sheet metal always use the smallest wire diameter possible since smaller wires take less heat to melt and heat the metal less. In this video im showing you the process i use to do small rust repairs where a complete panel. The rest is up to what way you are doing your welding and what results you want to achieve but it is also essential to take proper safety measures as well.

Small wires also provide more control over the weld bead and a better chance of recovering from mistakes due to lower deposition rates. If you re repairing an old car then you ll almost certainly need to weld rusted sheet metal at some point. Gaps between the pieces to be welded can contribute to warpage. Sometimes even professional welders may have trouble in welding thinner materials.

Here s a few tips on repairing rust holes in car body panels. For cv mig welding on sheet metal wire diameters of 035 inch are recommended. Rusted body panels need to be repaired. Novice welders need to understand that every material demands a different approach.

It s one of the highest quality machines available and comes incredibly low priced.