Miller 255 Pulse MIG

[redheelerdog]

Below are some pictures of welds made with the Miller 255 pulse MIG (Grader Scraper build)

I have had the machine for about 3 weeks and it is amazing.

Starting to get the feel for the pulse settings. The noise is quite different but I am getting used to it.

These are just flat welds, and they are amazingly clean in an as welded condition.

030" ER70-S6 C10 gas (90 Agon/10 CO2)

 

[Big Barn]

Nice!

 

[Big Barn]

And good idea on the clamps.

I chopped mine

 

[coxhaus]

Beautiful welds.

 

[redheelerdog]

And good idea on the clamps.

I chopped mine

View attachment 645642

Some styles of the Stronghand clamps have reversible hand screws so you can flip them around.

I thought about chopping mine but did not want to prevent the functionality of using them somewhere other than the welding table.

So far they have worked out good, had them for about a year now.

Is that a round welding table? That is cool! :thumbsup:

 

[Big Barn]

Is that a round welding table? That is cool! :thumbsup:

Yes it is.

Turntable With Track System
https://www.tractorbynet.com/forums/showpost.php?p=5589727

 

[Smokeydog]

Modifying clamps to hold down have been handy. This design can take full clamp pressure.

 

[metalbender]

Just a litrle off topic. Love to see clamping solutions. My table is laser cut for accurate corners and slots like the Miller table. Really like the Miller clamps, though others also work well. The frame is set in three inches all around for edge clamping. Lots of clamp options.

 

[BrokenTrack]

When I first started with pulse welding, it was really tough, but I swore it was not going to get the better of me. Now I prefer it.

Taking that peak out of the sinewave really cuts down on the heat, and allows for a much cooler weldment without sacrificing weld integrity. It is a little light for me on vertical welds, (UP), still, if the steel is there, I will switch to flux-core and pound in the wire.

 

[yomax4]

When I first started with pulse welding, it was really tough, but I swore it was not going to get the better of me. Now I prefer it.

Taking that peak out of the sinewave really cuts down on the heat, and allows for a much cooler weldment without sacrificing weld integrity. It is a little light for me on vertical welds, (UP), still, if the steel is there, I will switch to flux-core and pound in the wire.

Agree. Pulse is in every ones future. I have a variable twin pulse machine and run pulse for speed and twin for looks. Fun stuff.

 

[BrokenTrack]

Agree. Pulse is in every ones future. I have a variable twin pulse machine and run pulse for speed and twin for looks. Fun stuff.

I agree 100%.

At the shipyard where I used to work, and now at the shop (I am a welding instructor) we have Miller 350 Inverters, and you can really dial those welders in once you start messing with the programs. They are a little slow for my tastes in regards to vertical-up welds, but there is flux-core for that.

I was thinking about this thread last night as I went to bed, and I think I am certified to weld down in pulse-mode. I am pretty sure I took that weld-test, but it was a long time ago so I would have to check.

 

[BrokenTrack]

For speed I like spray-arcing. You can only do it on the flat, but can you ever pound out the weld-inches doing that.

Just for fun, I was welding a missile silo up one time that took 155 passes to make the fillet weld on the 4 inch thick plate. I had to run (2) guns because they would get too hot to hold after awhile, but I ran 5-1/2 rolls of wire in an 8 hour shift. That was 55 pounds of wire. I cannot remember the exact settings, but it maxed out the welder, and it was a Miller 450 and not the 350. I think it was at, or just over 700 inches a minute on amps, and 27 volts.

We were a Union Shop so the wire cribs would only let you take out (2) rolls of wire per day, so I had to stock-pile it in my locker for a few days to do it, but I really laid down the wire that day.

I would even spray-arc hull seams because it was so much faster. They always passed x-ray so it was a good enough welding process.