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An old timer once told me that "overhead is just like flat except upside down"
I think that is only partly true but I really struggled with overhead stick welding while I was in welding school.
I thought I needed to weld it cold so that it wouldn't fall out.
Once I learned to hold a tight arc, I could use the same amperage as I used on a 2F tee and things worked out better for me.
I think realistically, bumping amperage down to about 120-125 for 7018 overhead works pretty well with less tendency for arc blow toward the end of each rod but I just wanted to show that both 2f and 4f tee joints could be welded at 130 amps with a 1/8" 7018.
7018 electrodes from different companies all have slightly different amperage ranges too. Some run better at 135 , some run better at lower amps.

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I got a comment from a student a few weeks ago who was having trouble with a multi pass, fillet TIG weld at his welding school.

The conversation went like this.

“Hey Jody. Any chance of doing a 2F 6-bead to joint on 1/4 steel with TIG? Kinda having trouble with that in school for some reason. Doing the lay wire technique and this joint just will not come out like it is supposed to. The root goes in fine, but subsequent passes are harder to get in for some reason”

ME

“I will put it on my list but you will probably be done before I could get it shot lol. But let me ask some details anyway...Is it a tee joint? stringers or weave? and are you required to do lay wire? Any particular size wire? If root goes in good, but subsequent passes go bad , it could be surface oxidation so a gas lens might help along with letting it cool between passes along with wire brushing every pass.”

@connormarek1028

“Hi Jody. No worries. I`m sure it will take time to get videos out. I can answer your questions though.

1. 2F T-joint on 1/4 carbon steel plate.
2. stringers (but slight weave) and I`m required to do lay wire for some reason. Walking the cup is not allowed at all BTW. My instructor wants 6 beads.
3. 1/8 ER70S-6 filler rod. I`m welding @ 140amps on a Lincoln Aspect using Hi-freq start W/ a foot pedal. We also use gas lenses on our torches with #6 cups at ~30CFH. Maybe some surface oxidation, but only the "pretty colors" 😉. “

I am not sure why his instructor required lay wire technique, 140 amps, and a #6 cup at 30cfh but I would guess its because that would be fairly common for socket welds on 2 inch pipe.

30 cfh seemed a bit high even for a #6 gas lens cup…but maybe not if there is a slight breeze or draft.

I chose a #7 stubby gas lens and went a bit hotter while still using laywire and 1/8” ER70S6 wire.

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This video shows some differences in the arc plume when using different size tungsten electrodes.
Some textbooks will tell you to use the smallest size electrode possible.
But maybe there is more to it.
Using a small diameter tungsten makes the electrode get much hotter and seems to affect the arc plume quite a bit.
I was surprised to see a more confined arc using a 1/8" tungsten.

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This is the second revision for a display for my TIG finger® product.
I used .063" tread plate for this one.

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this video shows stick welding overhead using a rooftop joint and 7018 3/32" rods

Feeding filler metal tips and techniques.
The video on this page is about feeding the tig rod and some tips for getting that filler rod hand up to speed.

When you are first learning to TIG weld, one of the hardest parts is feeding the filler rod.

I supposed its because we have all been writing with our dominant hand since kindergarten but we did not get that early training with our non dominant hand.

One of the things that really helped me get better at feeding tig rod was tig welding aluminum parts on a positioner.
So in this video, I chucked up a 3 inch diameter aluminum tube and stacked beads to demonstrate feeding tig rod.

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filler metal charts and resources

https://www.esabna.com/shared/documents/litdownloads/alc-10030c_alcotec_alloy_selection_brochure.pdf

http://www.alcotec.com/us/en/support/Alloy-Selection-Chart.cfm

https://www.washingtonalloy.com/wp-content/uploads/2020/12/stainless-selector-guide.pdf

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When a welding procedure specifies a certain filler metal, then that is the filler metal.
but sometimes you are the one that selects the filler metal and so I hope this video serves as a guide for best practices.

it seems like higher AC frequency settings have a similar effect as high speed pulse does on DC.
In this video, I show a few different welds using different AC frequency settings and also compare clear cups to pink cups.
I used the primeweld TIG325x for this video and am really enjoying welding with it.
you can learn more about the TIG325 here https://weldmongerstore.com/collections/primeweld

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In this video, I welded with ER70S2, ER70S6 AND ER309 TIG ROD.

The differences betwwen ER70S-2 AND ER70S-6, are subtle except for open roots or full penetration welds.
ER309 tig filler rod is great for certain applications.'
'

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The challenge with a 1/4” aluminum single pass lap joint is getting penetration into the root of the joint...while at the same time, not chopping up the edge.
It can be difficult to hit the root while not chewing up the corner.
So I tested a single pass weld along side a 2 pass weld to check for depth of penetration.
I set the Primeweld TIG325 to 250 amps so that I would have extra power at first when the aluminum was cold.
AC frequency was set to 150HZ to focus the arc.
I used 3/32" 2% lanthanated tungsten and a #5 clear cup for the first welds.
I noticed some oxides floating around in the puddle with the #5 cup so I switched to a #6 gas lens cup for the 2 pass weld.
I use clear cups a lot for filming but I think a pink ceramic #6 gas lens cup is a good cup for a whole lot of aluminum jobs.
Penetration to the root was not that great on the single pass welds.
So I decided to try welding 2 passes....one focussing on penetration...and a second pass to get the adequate weld size.
A cut and etch test revealed much better penetration in the root of the 2 pass weld.
But because I didn't clean the aluminum at all before welding, there was a large pore.
That in itself is a lesson.
I should have taken a few minutes to wipe the aluminum with acetone and wire brush with a clean stainless brush.

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The primeweld TIG 325x has a low 5 amp start as well as great amperage range up to 325amps for thick aluminum.

I don't know of any other 325 amp tig welding machine that is this affordable and where the company has a great track record of customer support.

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I showed the rule of 33 pulse settings for thin steel where pulses per second, background current, and pulse width are all set to 33. The rule of 33 is a great way to remember good starting point for high speed pulse settings.
I used a low AC frequency of 50 hz on the 1/4" thick aluminum corner joint because I like lower frequency settings on thick aluminum corner joints.

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this is a 2g pipe weld on 2 inch schedule 80
35 degree bevels with 1/8" gap using 1/8" er70s6 filler rod
100 amps all the way out with 1/8" er70s6
Andrew Cardin is doing the welding while I run the camera and talk about whats going on.

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In this video I went over the spool gun features and highlighted some of the nice features this small mig 180 welder has to offer.

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Full article here https://weldmongerstore.com/blogs/weldingtipsandtricks/tig-pro-kit-tips-for-tig-welding-carbon-steel-4130-stainless-steel-aluminum-and-titanium
Cleaning the metal prior to tig welding is still a fundamental that a lot of people skip.
Hot rolled carbon steel can have a very thick layer of mill scale that needs to be completely removed and not just polished over.
Heavily oxidized aluminum also needs to be cleaning using an abrasive that is designed for aluminum with light pressure so as not to smear oxides.

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Wire fed welding processes like short circuit mig, spray mig, and dual shield flux core have very wide ranges of travel speeds.

Stick welding, while a very good welding process, has a much narrower range of travel speed.

Stick welding excels outdoors, for pipe welding, and one off welds or repairs.

But for production, wire fed processes can make you a lot more money.

Especially bare wire where this is no slag to chip and almost no cleanup.

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In this video you will see pulse spray mig compared to short circuit mig on a 3G plate 3/8" thick with 30 degree bevels.

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this is a 2g practice plate with 6010 root and 7018 fill and cap.

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