Tips & Techniques for Welding Vertically with Various Processes
Welding is a skill that can be used for various purposes, such as repairing, fabricating, or joining metal parts. However, welding is not always done on a flat surface. Sometimes, you may need to weld vertically, which means welding on a joint that is perpendicular to the ground. This can be challenging, especially for beginners, as gravity can affect the molten metal and cause defects. In this article, we will explain how to weld in a vertical position with different processes, such as stick, MIG, TIG, and flux-cored welding. We will also provide some welding tips and welding techniques to help you achieve a successful vertical position weld.
I. What is Vertical Position Welding?
Vertical position welding is one of the four basic welding positions, along with flat position welding, horizontal position welding, and overhead position welding. In vertical position welding, the joint’s axis is vertical to the ground at an angle ranging from 45° to 90°. Vertical welding can be done in two directions: upward or downward. Each direction has its advantages and disadvantages, depending on the type of metal, thickness, process, and desired outcome.
1) Upward or Uphill Welding
Upward or uphill welding is when you start from the bottom of the joint and move upward. This is the most common and recommended way to weld vertically, especially for thick metals. Uphill welding offers better control over the weld pool and deeper penetration into the base metal. This is because gravity pulls the molten metal downwards, so the arc points to the exposed base metal and melts it faster and deeper. Uphill welding also allows you to see the weld pool clearly and adjust your speed and angle accordingly.
However, uphill welding also has some drawbacks. It requires a lower amperage and a slower travel speed than flat or horizontal welding. This means that it takes more time and consumes more filler material. Uphill welding also produces more heat input into the metal, which can cause distortion or warping. Therefore, it is important to preheat and post-heat the metal properly to avoid these issues.
2) Downward or Downhill Welding
Downward or downhill welding is when you start from the top of the joint and move downward. This is a faster and easier way to weld vertically, especially for thin metals. Downhill welding produces less heat input into the metal, which reduces distortion and warping. It also requires a higher amperage and a faster travel speed than uphill welding. This means that it takes less time and consumes less filler material.
However, downhill welding also has some disadvantages. It offers less control over the weld pool and shallower penetration into the base metal. This is because gravity pushes the molten metal downwards, so the arc points away from the exposed base metal and melts it slowly and shallower. Downhill welding also makes it harder to see the weld pool and adjust your speed and angle accordingly.
II. How to Weld Vertically with Different Processes
The process you choose for vertical welding depends on several factors, such as the type of metal, thickness, joint design, position, direction, quality requirements, and personal preference. Here are some general guidelines on how to weld vertically with different processes:
1) Vertical Stick Welding Tips:
Stick welding or shielded metal arc welding (SMAW) is one of the most popular processes for vertical welding. To stick weld vertically:
Choose an electrode that matches your base metal type and thickness. For example, use E6010 or E6011 electrodes for mild steel up to 1/4 inch thick.
Set your amperage according to your electrode size and type. For example, use 75-125 amps for 1/8-inch E6010 electrodes.
Hold your electrode at a 90-degree angle to the joint and push it along the joint in an upward direction. You can use your other hand to help stabilize the electrode as you weld.
Maintain a short arc length of about 1/8 inch or less. This will help you control the weld pool and prevent sagging or dripping.
Use a steady motion and keep your travel speed consistent.You can use a slight side-to-side weave or a triangular pattern to fill in the joint.
Pause briefly at each side of the joint to ensure good fusion with the base metal.
Break off the slag after each pass with a chipping hammer or a wire brush.
2) Vertical MIG Welding Tips
MIG welding or gas metal arc welding (GMAW) is another common process for vertical welding. To MIG weld vertically:
Choose a wire that matches your base metal type and thickness.For example, use ER70S-6 wire for mild steel up to 1/4 inch thick.
Set your voltage and wire feed speed according to your wire size and type. For example, use 18-20 volts and 150-200 inches per minute for 0.035-inch ER70S-6 wire.
Hold your welding gun at a 5-15 degree angle to the joint and push it along the joint in an upward direction.You can use your other hand to help stabilize the gun as you weld.
Maintain a short stick-out of about 1/4 inch or less. This will help you control the weld pool and prevent sagging or dripping.
Use a steady motion, and keep your travel speed consistent. You can use a slight side-to-side weave or a triangular pattern to fill in the joint.
Pause briefly at each side of the joint to ensure good fusion with the base metal.
Clean off the spatter after each pass with a chipping hammer or a wire brush.
3) Vertical TIG Welding Tips
Tungsten inert gas (TIG welding) or gas tungsten arc welding (GTAW) is one of the most advanced processes for vertical welding. To TIG weld vertically:
Choose a tungsten electrode that matches your base metal type and thickness.For example, use 2% thoriated tungsten electrodes for mild steel up to 1/4 inch thick.
Set your amperage according to your electrode size and type. For example, use 80-120 amps for 1/8 inch 2% thoriated tungsten electrodes.
Hold your torch at a 10-15 degree angle to the joint and push it along the joint in an upward direction. You can use your other hand to help stabilize the torch as you weld.
Maintain a short arc length of about 1/16 inch or less. This will help you control the weld pool and prevent sagging or dripping.
Use a steady motion and keep your travel speed consistent. You can use a slight side-to-side weave or a triangular pattern to fill in the joint.
Feed the filler rod into the leading edge of the weld pool at a 90-degree angle to the joint.Use a filler rod that matches your base metal type and thickness. For example, use an ER70S-2 filler rod for mild steel up to 1/4 inch thick.
Pause briefly at each side of the joint to ensure good fusion with the base metal.
Clean off the oxide layer after each pass with a chipping hammer or a wire brush.
4) Vertical Flux-Cored Welding Tips
Flux-cored welding or flux-cored arc welding (FCAW) is a variation of MIG welding that uses a tubular wire electrode filled with flux instead of a solid wire electrode. To flux-cored weld vertically:
Choose a flux-cored wire that matches your base metal type and thickness. For example, use E71T-11 wire for mild steel up to 1/4 inch thick.
Set your voltage and wire feed speed according to your wire size and type. For example, use 18-20 volts and 150-200 inches per minute for 0.035-inch E71T-11 wire.
Hold your welding gun at a 5-15 degree angle to the joint and push it along the joint in an upward direction.You can use your other hand to help stabilize the gun as you weld.
Maintain a short stick-out of about 1/4 inch or less. This will help you control the weld pool and prevent sagging or dripping.
Use a steady motion and keep your travel speed consistent. You can use a slight side-to-side weave or a triangular pattern to fill in the joint. Pause briefly at each side of the joint to ensure good fusion with the base metal. Break off the slag after each pass with a chipping hammer or a wire brush.
III. Conclusion
These are some general tips and techniques on how to weld vertically with different processes. However, the best way to learn and improve your vertical welding skills is to practice and experiment with different settings, angles, speeds, and patterns. You can also check out some of the products from Megmeet Welding, a leading manufacturer of welding machines and accessories. They offer high-quality and innovative solutions for various welding applications and share free welding tips, such as overhead arc welding and 4 basic welding positions. You can also read their informative articles on their website to learn more about welding topics and trends.
