wrought iron fence repair: wire and settings needed.

[johnnymg]

Big Greetings

I'm going to be repairing an old wrought iron fence and would like some recommendations on what process/materials to use. I'll likely use my imig 200 so settings/wire recs for OUTDOOR welding is what I'm looking for. I have a bunch of ER70S wire (in the usual suspect sizes) but I'm thinking that maybe a dual shield wire would be better for outdoor welding. ????

FWIW, the square tubing I'm repairing into is somewhat "worn". i.e. a bit rusty inside. This is mostly a cosmetic repair for now.

thanks a bunch!
JohnG

[Rambozo]

Big Greetings

I'm going to be repairing an old wrought iron fence and would like some recommendations on what process/materials to use. I'll likely use my imig 200 so settings/wire recs for OUTDOOR welding is what I'm looking for. I have a bunch of ER70S wire (in the usual suspect sizes) but I'm thinking that maybe a dual shield wire would be better for outdoor welding. ????

FWIW, the square tubing I'm repairing into is somewhat "worn". i.e. a bit rusty inside. This is mostly a cosmetic repair for now.

Too bad it really isn't "wrought iron" but steel tubing instead. The iron would be easy. I just finished up a bit of that work with both stick and TIG but no MIG. The real problem is that the rust makes the tubing all different thicknesses. So expect to be tweaking settings as you move along. Try to figure out the real thin pieces if you can before welding. Tapping on them can help as the sound will change. If you have some scraps you have cut off, that will help but if not, dial your settings back and sneak up on it to prevent blowing through. Flux core would be nice if there is wind, but then your post weld cleanup will be a pain. I would first try to set up something to shield you from the breeze if it's not too bad. Just a tarp or a sheet of plywood can make all the difference.

[johnnymg]

Too bad it really isn't "wrought iron" but steel tubing instead. The iron would be easy. I just finished up a bit of that work with both stick and TIG but no MIG. The real problem is that the rust makes the tubing all different thicknesses. So expect to be tweaking settings as you move along. Try to figure out the real thin pieces if you can before welding. Tapping on them can help as the sound will change. If you have some scraps you have cut off, that will help but if not, dial your settings back and sneak up on it to prevent blowing through. Flux core would be nice if there is wind, but then your post weld cleanup will be a pain. I would first try to set up something to shield you from the breeze if it's not too bad. Just a tarp or a sheet of plywood can make all the difference.

Yes, this old fence is just plain steel square tubing.

Hmmmmm, I have some unopened 3/32" 7018. Do you think that would work or will I likely need even thinner rod. The tubing is pretty thin. I do have a bunch of "spare" tubing so have plenty of practice material.

One additional plus for the stick process is that I wouldn't have to transport a gas bottle 400+ miles to the job site.

regards
JohnG

[DaveO]

What kind of joints, just for curiosity? I'm wondering if a 6013 electrode for low penetration might help. I've seen them in 1/16".

[performance]

If you are joining any cast iron decorations, use 6011 to join it, don't use mig wire or you'll rue the day.

[Mr120]

If you are joining any cast iron decorations, use 6011 to join it, don't use mig wire or you'll rue the day.

Good point about MIG and cast iron. I've heard that can have issues. What exactly is going on that can make a MIG welded cast iron part problematic?

[sportbike]

If you are going to use flux core, make sure you practice with it a bit first, it welds differently than using solid wire and gas.

[zoama]

I'd use .030 flux core in the mig welder.