TFS: How to Weld Thick Metal to Thin Metal

[@TheFabricatorSeries]

How to back purge: kzbin.info/www/bejne/d3q1iICepNCYb6s

[@tonyvtech25]

The Fabrication Series . HEY IS IT REQUIRE TO HOLD THE GUN CLOSE TO THE WELD FOR A SHORT PERIOD WHEN YOU STOP WELDING ? Cuz i can see that after you stop welding you let the tip cool down close to the weld and then you continue.. Is that require or is just you ?? LOL.

[@johnswilley6764]

From someone who taught and worked emergency services for >25 yrs., you Sir are an excellent instructor an communicator. Your explanation of rationale and technique are exemplary. I thank you. Please keep up the great work!

[@dbayboyds409]

I just referred back to this video and it is still excellent. It’s a shame I can’t like it twice! Thank you so much for the time and effort you put in to recording them. It is so helpful!

[@pyramidsinegypt]

Appreciate the metric sizes being mentioned aswell! Getting better at mental metric/imperial conversion, but nice to not have it distract from the rest of the video and explanations :)

[@krusher74]

yep only a few countries left in the world that arnt metric

[@quartfeira]

Me too! I usually have to pause and do the conversion 😅

[@tomf4547]

I agree, 'guage' means less to me than imperial sizes 😅

[@rjuarez4913]

A lot of experience passed on to us. All this great information so hopefully when the good the bad or the ugly hits, we will know why and can proceed accordingly. Thanks again Justin.

[@YT-User1013]

What a great video and great shot and technique of the tac weld. I could have used this same technique just the other day trying to weld 14 gauge mild steel rectangular tubing and not burn through the edge pieces!!

[@TrojanHorse1959]

Great video, thanks! This is pretty much the same as other forms of welding from what I understand. I was always told to focus the heat on the thicker piece.

[@GarryFullerSr]

Great Video. This is true also for MIG, and Stick. Weld from thick and wash up to the thin. I see you run a lot of stick out. I'll have to try that much on my next TIG weld. Thanks.

[@adamcain4603]

Your teaching commentary is excellent thank you

[@melgross]

When doing a tack like this I concentrate on the thick part. Wait for the puddle, and move it briefly to the thin part, which is now heated. A puddle forms almost instantly, and then I move it away. You can do it either way, but I regard it as safer starting on the heavier part. Of course, a lot of it is skill. If you are new to this, starting on the thin part is more dangerous, because it can be difficult, without experience, to tell when you’ve heated that thin tube enough, and you may be uncertain enough to leave it just a bit too long, and punch through. But when puddling on the thick part first, and that puddle forms on the thin part when you move the tip towards it, you will see them conjoin, so it’s easier to know that it’s done.

[@momobadilak]

great video ..appreciate the detail shots and explanation

[@jarebb1]

Great video once again.

[@66mybeat]

Awesome video! Thanks for the tips! I will be practicing again today!!

[@mike216ism]

Love the channel and your an excellent teacher! Much appreciated

[@nussberger]

Great video, thanks! One question thoug, how can you have your electrode stick out so far? Is that a special cup for the purpose?

[@nolanberry8155]

That black on the back is called superintendent or carbide precipitation it has to do with that stainless not being purged but also more so that you amperage is to hung and travel speed to slow the grate thing about stainless is it is stronger thus a smaller bead is ok

[@stizolac]

This video is exactly what I needed, thanks. In my application I'm welding 11 gauge to 3/8 plate MS, what amperage should I be using?

[@team8th]

what tungsten and filler rod were used in this video? did you keep the cfh around 20+?

[@paulmorrey733]

Thanks Justin

[@M240D]

This was very timely for me. What would we do without KZbin? Thanks!

[@chris_ennis2694]

Awesome video! Thanks for the info!!

[@ol-man-duffyj688]

Thanks for sharing. I’d love to see it done with with some aluminum foil Purge gas and show us the results. It’s cheap to purge with foil block off and. A small hose from the argon reg

[@WizardRench]

How long did it take you to be able to spin that practice piece on your finger without dropping it lol great videos

[@knonfs]

AWESOME vid! You should make a video of how to weld a pipe/tube to a vband flange.

[@TheFabricatorSeries]

knonfs My Raw & Uncut vid has footage of me doing that in it (twice I think). The exhaust vid has about 2 or 3 clips in it as well.

[@knonfs]

I've seen them. The thing is that I've heard that welding vband flanges without warping them is extremely difficult. If that's the case, I was wondering if you could cover that. I have not seen any youtube videos covering this, maybe its not that difficult?

[@TheFabricatorSeries]

The only time I see people warping is when they cranked too much heat into it. Either too much torch height or too much amperage will do that.

[@jimgam730]

Like the shorter video. I don't always have time to watch the longer ones.Can you make some more at around this length? Do you only use Everlast welders? Thinking about getting a tig welder and was leaning towards Everlast

[@almamabesa]

Excellent video - thanks

[@C.P.C.RACING]

What size of tungsten and filler rod where you using. Also great video.

[@WickedMoto]

What size filler were you using in this?

[@mohgujai]

Dat stickout doe...

[@ab_customz_llc]

Akane lol I was thinking the same thing. Taking full advantage of the #12 cup.

[@zipzit2go]

Nicely done presentation. One question for you.. It looks like you are using an old skool welding helmet without electronic auto darkening feature. Why that choice?

[@BeaverLakeMotorsports]

Can you do the same thing but with the tubes welded to a thin sheet that you don't want to warp?

[@TheFabricatorSeries]

I'll see what I can do.

[@duncanmacfarlane238]

Learned alot. Thanks for the instructive video.

[@vigwelding926]

I understand you say where the focus of the heat need to be, but what about the filler rod? Do you place it up on the wall of the pipe and let gravity pull it down or place it right in the groove and drag it up with the torch?

[@tomf4547]

I'm wondering what happens to the shielding gas with so much tungsten sticking out. We're taught to have very little tungsten showing while welding, although the cup would obviously get in the way here.

[@madams22100]

one of the best channels on youtube along with the fab forums channel.... keep makin them videos man....

[@TheFabricatorSeries]

Thank you

[@911engineguy]

I just started trying to Tig. My teacher (friend) has me using a much smaller cup and also to only let the tip stick out about 4mm from the edge of the cup. Where in this vid, you have a massive cup and the tip sticks out a mile! Is this necessary because you are welding inside a 'corner'?

[@julianalvarado93]

Awe oh my God justin I love ur vidoes😭😭 always helps me out when I'm in a pitch!! Always use ur vids for reference thank u brother!!! Keep being awesome!

[@itoroots7291]

Great video and great tips

[@AviantoMr]

what an invaluable tutorial. Thank you very much for "the detail tutorial. By the way, I still have a problem in the way to devide a 100cm x 10cm x 1cm raw SLD Hitachi D-2 steel material to be 2 pieces of it sizing 100cm x 4.95cm x 1cm "without making a big chage of the quality of the material at the line of cutting. I do not know what is the best way to do it with. May be you have some advices for me to learn with. THank you very much again for each of your knowledge sharing. GBU always.

[@weldingjunkie]

Great video man. Was that a HTP TLP I saw up on the Great Wall of welders? What an awesome machine. Thanks for the flange tube focus point for puddle I always struggle with where do I focus the tungsten. I always struggle with getting a good fast tac too I have to get a puddle to tac.

[@Anglgrinder-j3y]

Thank you very much, super helpful... You Rock

[@JoseMendez-qx9mr]

Awesome video

[@jonathanwiggill8242]

Much Appreciated Tutorial - Thank you

[@beatricethemiata8565]

Do u have an up to date video of this on mig welding???????????

[@TheFabricatorSeries]

I can make one.

[@consun14]

I would love one

[@sidewaysdanny]

Very similar technique, but you weave slightly, holding on the thicker material for slightly longer than thin as you move side to side.

[@williammccourt7581]

I would also love a video for mig! Currently mapping out a tube-front-end for my drift car and 99% of the welding I do is simple exhaust work, so I don’t have much confidence in welding the plates to the strut towers and thinner (unibody) frame rails.

[@nickoli9889]

Was going to ask this too, would be super helpful. Although the technique is probably similar, I imagine many of us who run MIG would still benefit from seeing how you do it

[@danh7203]

Great video. Thank you.

[@jeffyoung922]

Hi Justin why how did you work out to use 100 amps for these welds thanks Jeff

[@hillbillyhangover]

Thank you thank you thank you!

[@kraut-performance]

Good clip, like everytime! But, with stainless, it's easy weld! I've allways little problems with 6061 and other AL. For example, at the wastegate 25x2mm welding to 60x2mm. The small tube allways runs away.... :-D

[@TheFabricatorSeries]

Focus the arc on the bigger tube when welding. Same rule applies.

[@kristijanmarin3437]

Hi, great video. I’m a newbe in tig and was just wondering how did you know that 100amps is the right amperage ? Rule of thumb for SS I think is around 35amps per mm ..... So is there a compromise between 10mm thick base and 1.6mm tube or how do you decide at which apms to start ? Thank you.

[@richardhoang1742]

I was thinking of the same question. I'm also a noob tig welder.

[@TheFabricatorSeries]

I'll try to make it make sense. There technically are no "rules" of TIG welding. What you find are guidelines and suggestions for running certain metals of similar characteristics. I based it on the amperage it takes to burn a certain amount of metal away that I know I want to burn. In this case, I want about an 1/8" (3mm) of the edge of the flange to burn for a good penetrating weld (1/3rd thickness of the flange). That would take somewhere between 100-120 amps to do depending on my speed, filler, and other factors. I was running extremely thin filler metal in this vid so everyone could see the shots, so I would have had to run a little faster to keep up with the puddle at higher amperage. Instead of flying right through it, I decided to take the low amperage of 100 amps and full throttle it all the way through which slowed me down enough to get a good shot, but still not too hot to where I would blow up the thin tube. If I ran 1/16th filler, I would have to increase my amperage a bit. The focus is also the key player in any metal you weld. If you have too much focus in the wrong place - you'll burn or blow it up.

[@briankeller3884]

Kristijan marin you set your heat to the size of your filler rod

[@TheFabricatorSeries]

brian keller I won't suggest that as a good or sure common practice. It's a common practice to follow "filler=amps", but I ran .045" filler on 100 amps. That's not even close.

[@briankeller3884]

The Fabrication Series .. fair enough but you could do that with anything .. you could use 045 wire while using 200 amps but its not the best... if your welding at a 100 amps using 045 chances are your feeding like crazy to satisfy the puddle or keep surface tension why not just use 3/32.... that being said every job is different and sometimes u need to do the job with what u got... anyway take care keep up the good videos

[@enricopietraroia5621]

How much cfm you working with with that stickout?

[@michaelcostello6991]

What size cup were you using. How critical is the cup size here. Was this a gas lens etc . Thanks

[@es47]

Do you have or can you make a video like this one with the purging to see inside of pipe afterwards? Great video btw good tips

[@TheFabricatorSeries]

Check this vid out kzbin.info/www/bejne/d3q1iICepNCYb6s

[@gallanonim2839]

Hi Justin, need Your advice or maybbe it could be idea for new episode. Im strugling with tig weld of two 2,5mm steel wires in parallell on bit long distance. Could You giive any hint?

[@mjgthakid]

How to tig weld thin to thick, good information but put that in the header, I am a lowly production welder with only mig and pulse mig at my disposal. Last night was welding expanded metal to 14 gauge to 3/16. And took way more time than I should have. Wish I could just whip out a tig torch for random parts.

[@dirtbikingskibum9727]

Thanks man!

[@stanzad9324]

Focus ha I think I’m ADD 🤣🤣🤣 thanks for the tip man it definitely help me to focus people.......

[@Kc07910]

That's crazy stick out what kind of gas flow are you using with that cup haha nice video man

[@TheFabricatorSeries]

It's not that far for the cup. Running about 25-30cfh

[@Kc07910]

Awesome think I'm gonna have to get me one of those cups

[@romanoschwabel3716]

how do you make it that the flange ( 10 mm thick ) will not bend because of the heat and when cool down again?

[@nicholashughes8173]

Hey Justin, new to fabrication, and to tig, you mention here the welds are much weaker when not back purged, I'm welding lots of 20mm x 40mm 1.5mm wall 304 box section at the moment, is back purging really needed?

[@christophermoyer9760]

Thx brother

[@meocats]

do you have to purge if you go for a 2nd pass from the inside at half penetration?

[@prodzektownia]

well explained!

[@oldmenruleracing]

Great tutorial! Just found you. Will subscribe

[@Zig285]

That stick out 😱

[@brucethomson2049]

How do you combat the undercut that you get sometimes when tigging heavy material? I've tried adding more filler but it still undercuts on the edge of the weld, even if go high or low with the amperage. If you focus your arc towards the undercut it doesn't help either. Usually on cast steel but sometimes just regular old mild steel?

[@84sportster1]

How does back purging work for flat stainless?

[@recrdholdr]

I will often preheat the thick flange a little bit.

[@Titantramp4u]

What size cup are using?...that's a ton of stick out on your tungsten...Thanks for the video.

[@mikeford963]

Titantramp4u The size of the cup is related to the stick out.

[@Matt_Holcomb]

Hey Justin what size cup are you using

[@stevenwilliams6963]

Could you do one for welding bungs to 1.5mm tube. Im really struggling to do 1/8npt fittings to pipes without completely mashing up the bung/threads itself :(

[@Manosadrt]

did you preheat that thick piece of metal?

[@antonioempleo3515]

Can i used tig on brass sheet? Please reply,,, thank you

[@jessc6687]

What type of metal tube is commonly used in muffler shops?

[@TheFabricatorSeries]

Jess C Aluminized

[@workingovertime4429]

G'day what I would like to see a video of is welding aluminium 2"od tube 1/16 wall to the end of 2"id pipe 1/4 wall the two pipes sit inside each other by 1/4" because I'm just burning the thin tube away

[@TheFabricatorSeries]

I'll see if I can find those sizes locally. The key word though is focus. There is a bit of a trick to aluminum, but the focus must still remain correct.

[@angelcisneros6632]

very nice!

[@TheDznuts]

What do you mean by Purge?

[@kendaily7061]

What do you mean by purged, I'm unclear. Thanks Ken.

[@TheFabricatorSeries]

Hey Ken, click the link in the top comment to learn about back purging.

[@jordanhammond92]

Question. I'm learning to TIG but thought your tungsten had to be closer to the cup. Why was yours so far out?

[@mikefurlong8025]

Running a longer stickout helps with being able to maneuver the torch to the correct angle in between pipes. However, he is only able to run such a large stickout due to the extremely large cup size he is running, and, I presume, a really efficient gas lens which helps him maintain gas coverage over the weld. For starting out, it's best to keep your stickout no more than the diameter of your cup. That should see you through the majority of your basic welds until you get a feel for torch angle, and when you start to lose gas coverage, etc. Good luck.

[@jordanhammond92]

@@mikefurlong8025 thanks man, always like helpful replies

[@ericcaldwell3584]

We don't Purge anything we weld here at our shop since we're not a code shop and we weld all stainless, sometimes aluminum. I was hoping to get some tips on how to not sponge through while welding thick to thin (currently I'm welding 12guage to 7guage (basically in the third configuration you showed)), but you absolutely obliterated it. You sponged through on the entire length of your welds except for your stops and starts. If I welded it like that here I'd probably get fired. I'm basically having to use the tungsten and filler wire to "splash" the puddle up onto the 12guage and the come back down and move to the next spot to create the ripples. Not trying to be mean here; just sharing how we would view that at our shop. I guess technically the way we do things here, we're not quite getting full penetration, but from my perspective, you got more than 100% penetration (like 110, 120, or 130% penetration) since it was starting to come out the other side (sponge through). My goal with what I'm doing is to get more penetration on the 7guage by focusing on it longer during each dime or bead or (I'm going to call them ripples) each ripple, then splash the 12 Guage, shove the rode, and move on. I'm currently at 143amps. I just have to adjust my speed to make sure I don't sponge through, and make sure I push enough rod (filler wire). I don't have the luxury of a pedal. It's just locked in at whatever amperage I set and it's either lift arc, or my dredded scratch start.

[@Turbo44mag]

The old way "consistent heat" you know what I'm saying

[@richardanderson9092]

I assume the concept is the same for MIG welding? If possible, would you be able to put a quicker video showing the same concepts with MIG? Something like welding rollbar backing plates to a factory floor plan. Thanks.

[@SOLDOZER]

Same applies with Mig. Focus on the thick piece and tie in to the thin piece.

[@TheFabricatorSeries]

It is pretty much the same as mentioned. I usually give a quick push into the root to make sure the puddle gets in there, but still the same concept of focus.

[@rosserpace3602]

What do you mean when you say you didn't purge the weld? Is this in addition to the torch gas?

[@split150]

Yes, it's having an argon environment inside the tube so the inside bead isn't exposed to atmosphere when welding. A purged inside would look like the outside weld bead, instead of the "sugaring" shown.

[@vincentkirouac9311]

Rosser Pace yes. Gotta have gas on the inside of the tube as well. You can close both ends with foil and pump gas in via a second line.

[@TheFabricatorSeries]

Check this vid about purging. I explain it all. kzbin.info/www/bejne/d3q1iICepNCYb6s

[@sproutandmerc1941]

Do you have to purge when you are doing that flush mount weld (your last one ) and if so how would you do that?

[@TheFabricatorSeries]

MasterMachinist WH There is technically no way to purge that unless you are in a chamber. Most of the atmosphere is driven out by argon, but some will remain in the gap and a small amount will sugar up. However, that's just a filler weld and not critical. The first weld would fail all day without purge.

[@Fullchiselchainsawartistry]

I am thinking about an everlast, it looks like all you run? It's AHP or everlast, do have an opinion? Thanks

[@TheFabricatorSeries]

I have Everlast, AHP, Miller, HTP and Lincoln. I kind of like them all for one thing or another, but the Everlast machines are pretty nice.

[@who_is_asking]

How much CFH of argon are you running with that long of a stick out? Gas lens?

[@TheFabricatorSeries]

William Preston standard gas lense at about 30 CFH. It's not as extreme as people think. The coverage is a lot better with the longer stickout.

[@who_is_asking]

The Fabrication Series visibility has to be perfect. I just bought my first gas lens and the supply store only had a number 8 pink cup for it. Just testing the limits an seeing the flow vs stick out values.

[@00camaro00]

Might have been asked,but didnt see it when i looked. Instead of back purging whats your opinion on using Solar flux for stainless in this type of situation?

[@TheFabricatorSeries]

I use it all the time.

[@00camaro00]

Thanks for taking the time to reply. Yeah just wanted to be sure it was exceptable in and header type situation. Always heard back purge only in that. Again thanks for taking the time to reply

[@TheFabricatorSeries]

00camaro00 Usually the biggest gripe is the glassy mess it leaves behind which can breaktfly off if not cleaned. That could damage or clog stuff.

[@alanmony1582]

It seems to me that the tungsten stick out is HUGE! Can you do that because of the Furick cup? Did you get that from Jody?

[@BevansMotorsport]

Alan Susnow i think he does it just to exaggerate in the video so we can see, i know for example in my work we would never have ot out that far, as the futher in it would be, would make for better colours and more focused gas coverage

[@alanmony1582]

I get that, but his welds look PDG even with that stick out. I recognize the #12 Furick gas lens cup that Jody sells at weldingtipsandtricks . Even with all that stick out you can still see the argon shield around the weld.

[@TheFabricatorSeries]

Alan Susnow It is a #12 Furick. I either bought it from TiCon Industries or Weldporn (can't remember). Stickout is roughly 3/4" which can operate like that all day and night with no issues. I also use a lot of stickout for weld shots because it's very difficult to get in close and see, but long stickout on the cup offers more coverage than short. That's what it's for.

[@alanmony1582]

Thanx, that's what I wanted to know! Love the Fabrication series, always good stuff!!

[@jamessonger3]

no you can weld all day everyday with that stickout.... rule of thumb is you can stick out the tungsten the same distance that the ID of your cup is... thats a #12 cup he was using...

[@Ma_X64]

Q: Can we purge this kind of things with just peace of solid carbon dioxide? Solid carbon dioxide is cheap.

[@nicki9894]

+1 for the Ticon sticker!

[@aaahtex902]

HOW do you PURGE???

[@jonlittle346]

what is the amp.

[@phonypony5.0]

jeff luts doesnt back purge lol he get mad when someone tells him you have to lol

[@mambamentality2663]

Can you make thin metal to thick????

[@ThePimpstick420]

If you look in the right hand side of the weld inside the red circle long enough at about the 3:40 mark you can see a dolls face

[@TheFabricatorSeries]

I really tried to see it.... I guess I need to be what you're on for that.

[@addigital6981]

EXCELENTE VÍDEO!

[@lkjyuiop1987]

I. TIG SS at work I like to watch videos about welding you can always learn something new I make car wash vacuum cleaners make 23 in a 10 hr day. Ever weld with really thin tungsten? The smallest

[@apacheone3643]

How do you weld any metal with a NEVERLAST?

[@TheFabricatorSeries]

CRAZY HORSEPOWER Same way you do it with a lowsy beer, a dead president, or a bumble bee. I actually used my HTP for this vid.

[@apacheone3643]

The Fabrication Series So why show a bunch of Neverlast welders,Those who either own them or work in welding supply stores that repair welders know that cannot be repaired due to no parts.I would not want to be caught dead sponsoring a Company that has some of worst complaints I have ever seen including a welder that was not certified 5 years ago.

[@TheFabricatorSeries]

CRAZY HORSEPOWER I think you're caught up on some once upon a time action with Everlast. They're not what they used to be.

[@apacheone3643]

The Fabrication Series I have a friend in a welding supply that repairs welders the two welders he turns away a lot is first the Everlast especially the 256s plasma,tig and arc welder AC/DC machine the mainboard fails a lot. They cannot get the boards to repair them and if he does it usually takes 7 months to a year,The second one is ESAB as they are a better company than NEVERLAST it still takes a couple of months to get parts. Lastly I do know for a fact the owner and CEO for Everlast has a long track record with THE BETTER BUSINESS BUREAU IN Califorina as to not honor the supposed 5 year warranty.One guy has a pending case that has been going on about 5 years by now. As for Me I know for a fact the owner is a snake in the grass as I personally have had caught him in a lie when he left a message on my answeringmachine he IDENTIFIED himself as being from Costomer service from AMAZON then later on in the recording claims he is A REP FOR AMAZON then finally he says he is from Neverlast.Also The recording was sent to Amazon and Corporate was not pleased.So if I were you I would question them and ask the owner what relationship he had with the Owner of Longevity all though it has little to do with welder what it does have to do with is business practices with the public.I do not need to prove what I say as the information is out there call Mr Tig,Call Kevin Carroll,Call B.B.B.they may enlighten you as they have machines that were in need of repair.

[@TheFabricatorSeries]

CRAZY HORSEPOWER I'll be straight up with you - I really don't bother worrying about anything until I have to. It's all hearsay until I experience something. My experience thus far with my machines and customer service has been good. If it changes, I'll be sure to alert my audience about my experience, but at this point, I have nothing to say other than I don't share your experience or the experiences you report about othets. I'm not going to worry about it until I have something to worry about.

[@BilkoGod]

Isnt that a fillet weld?

[@TheFabricatorSeries]

Bilko101 Depends on who you ask haha. It's technically both. Fillet by the book definition, but different depending on industry term. It's weird like that and you'll probably see both sides argue it if these comments take off.

[@BilkoGod]

Yeah haha I had a little argument with myself about it

[@koitorob]

Once more in aluMINium please

[@jean9910]

What is purging?

[@TheFabricatorSeries]

Check this vid out. It explains it all. kzbin.info/www/bejne/d3q1iICepNCYb6s

[@SOLDOZER]

Its something you have to do with stainless Tig welding that wastes all your gas. Just stick weld it!

[@jean9910]

Thx!

[@jean9910]

I know how to stick weld I'm comfortable with it. I have a tig and I was to learn how to use it.