Spot welders......

[Phil Waterman]

Hi Bob

I'll check the Miller web site to see I can figure out what is going on. Try and figure out how or if model 52 is different from mine. My welder always seems to work well with fresh steel. Or with steel that I have cleaned all the surfaces have been cleaned real well. Best tool for cleaning the steel without grinding away material are the 3m abrasive pads for the air grinder.

Funny you should ask this question now as two weekends ago we had our MV club's annual welding seminar at my place and one of the things we spent a lot of time on was spot welding. and the metal prepping.

Cheers Phil

[Phil Waterman]

Hi Bob

Want to check I've got the correct model. LMSW-52 220 not the LMSW-52T 220 W/WELD TIMER

http://www.millerwelds.com/products/...__air-cooled_/ I'll start reading

Here is the web site for the spot welder I have http://www.htpweld.com/products/spot...quickspot2.htm


Hi Bob

Just found that I need the serial number to be able to down load the manuals.

[Phil Waterman]

Hi Bob

Was able to down load the current version of the manual and read through it. Couple of points:

1. I wouldn't run out and buy the timer unit. Think the problem is not lack of auto timer. Half the time I do the welds almost by ear and eye. Sound of welder changes as metal heats.
2. Try some sample welds after cleaning all four sides of the metal and post some pictures (or e-mail them to me)
3. Do you have a AC volt meter that one of the guys could read the voltage of the 220 voltage going to the welder. I had problems with mine when I built the barn as it was fed from the house to garage to barn to much line drop. While your at it check both legs of the power panel. I have to turn off the halogen shop lights when I'm weld sheet metal to angle iron with the spot welder.
4. Can not over empathizes need to clean/polish the steel.
5. I've made up some sample combination sheet metal thicknesses to put between the tips when setting the tip pressure. On them I've written the weld time and heat setting.
6. Just as with any other type of welding when you have not done it for awhile you have to practice, I have to force myself to practice until I get good again time.
7. The manual is correct about shape and size of tip contact area being important.
8. Holding the pinch pressure until the metal is no longer red hot is also important and a problem that I had trouble with until I remembered that you have to hold the pressure after releasing the trigger. Some thing like a three count should do it.


Await the results of further test.

Cheers Phil

[Bob Carriere]

Hi Phil.....

1. I wouldn't run out and buy the timer unit. Think the problem is not lack of auto timer. Half the time I do the welds almost by ear and eye. Sound of welder changes as metal heats.***How long do you leave the power on...?
2. Try some sample welds after cleaning all four sides of the metal and post some pictures (or e-mail them to me)....that maybe my problem...I used scrap metal with some surface rust bloom......
3. Do you have a AC volt meter that one of the guys could read the voltage of the 220 voltage going to the welder. I had problems with mine when I built the barn as it was fed from the house to garage to barn to much line drop. While your at it check both legs of the power panel. I have to turn off the halogen shop lights when I'm weld sheet metal to angle iron with the spot welder.....I have a 200 amp service dedicated to the barn as a seperate service.......
4. Can not over empathizes need to clean/polish the steel........ will do new samples with new clean steel....
5. I've made up some sample combination sheet metal thicknesses to put between the tips when setting the tip pressure. On them I've written the weld time and heat setting......Good suggestions....
6. Just as with any other type of welding when you have not done it for awhile you have to practice, I have to force myself to practice until I get good again time.
7. The manual is correct about shape and size of tip contact area being important.....I have new tios and spare tips.... how often do you redress..as in how many cycles/spot welds between dressing
8. Holding the pinch pressure until the metal is no longer red hot is also important and a problem that I had trouble with until I remembered that you have to hold the pressure after releasing the trigger. Some thing like a three count should do it. .....never had to do that..... I barely cycle the switch on for a fraction of a second and it burn a hole and throws sparks all over... the metal prep may be my single biggest problem

Will cut some new strips in new clean metal....degrease.... various gauges primarily 18 G and 14 G at this time...

Stay tuned...

Bob

[Phil Waterman]

Hi Bob

Sounds like good starting points, after you try some more experiments and send photos we should know more.

I'll check the actual cycle time on mine welding at different settings.

When you take your pictures include on of the tips. I have differ size tips and the small ones will burn through more easily than the big rounded ones. I'll take some photos of the tips I have.

Glad to here you have a separate power service to the barn, when I redid ours to install the generator transfer switch I separated house, garage, and barn. Which solved a lot of my problems. I've still got a problem in the barn that I've got to shift around, all the lights ended up on one side of the circuit.

Cheers Phil

[Anthony Main]

The metal you intend to spot weld needs to be clean, No rust or paint
as this stops the welder making a proper electrical conection between
the metal & Blows holes instead of welding!

[Mike K]

I live in a rural location and the mains voltage drops down each afternoon , around 4-5pm. Welding jobs after 5pm are hopeless.

Has anyone successfully spot welded aluminium sheet panels ? I've seen it done by a chap here who makes new Land Rover body tubs.
Mike