Introduction
This manual provides essential information for the safe and effective use of the Forney 42466 Low-Hydrogen Welding Electrode. This electrode is designed for welding mild steel, particularly in applications where conventional rods might lead to excessive porosity.
Please read this manual thoroughly before use to ensure proper handling, optimal performance, and safety.
Image: A cardboard box containing four green plastic containers of Forney E7018 Low-Hydrogen Welding Electrodes. Each container is labeled with "Forney E7018", "5/32" (4.0mm)", and "10 lbs. (4.5kg)".
Safety Precautions
Welding involves significant risks. Always adhere to the following safety guidelines:
- Wear appropriate personal protective equipment (PPE), including a welding helmet with a proper shade, flame-resistant clothing, welding gloves, and safety shoes.
- Ensure adequate ventilation to avoid inhaling welding fumes.
- Protect bystanders from arc rays and hot metal.
- Disconnect power to the welding machine before performing any maintenance or changing electrodes.
- Store electrodes in a dry, controlled environment to maintain their low-hydrogen properties.
Setup
Before beginning any welding operation, ensure your equipment is properly set up.
- Prepare the Welding Machine: Ensure your arc welding machine is in good working order and set to the appropriate current type (DC+ or AC) and amperage for E7018 electrodes. Refer to your welding machine's manual for specific settings.
- Electrode Selection: Select the correct diameter of Forney 42466 (E7018) electrode for your application. The 15-inch length provides extended reach.
- Workpiece Preparation: Clean the base metal thoroughly, removing any rust, paint, oil, or other contaminants that could affect weld quality.
- Ground Clamp Connection: Securely attach the ground clamp to the workpiece or welding table, ensuring good electrical contact.
- Electrode Holder: Insert the electrode firmly into the electrode holder.
Operating Instructions
The Forney 42466 is a low-hydrogen electrode, ideal for welding mild steel, especially in applications like field erections, steel structures, frames, trailer hitches, and chassis. It is also suitable for cold rolled steels that might exhibit excessive porosity with conventional rods.
Welding Techniques
- Arc Starting: Use a scratch start or tap start method. E7018 electrodes can be slightly harder to start than other types.
- Arc Length: Maintain a short arc length, typically equal to or slightly less than the electrode diameter. This helps maintain the shielding gas and prevents porosity.
- Electrode Angle: Hold the electrode at a slight drag angle (10-15 degrees from vertical in the direction of travel).
- Travel Speed: Maintain a consistent travel speed to ensure proper penetration and bead formation. Too fast can lead to shallow penetration; too slow can cause excessive buildup and overheating.
- Weave Pattern: A slight weave or stringer bead can be used depending on the joint type and desired bead profile.
- Crater Fill: At the end of a weld, pause briefly to fill the crater and prevent crater cracking.
Recommended Amperage
Amperage settings vary based on electrode diameter and welding position. Always refer to the electrode manufacturer's recommendations or a welding chart. For general guidance:
| Electrode Diameter | Amperage Range (DC+) |
|---|---|
| 3/32" (2.4mm) | 75-125 A |
| 1/8" (3.2mm) | 100-160 A |
| 5/32" (4.0mm) | 140-220 A |
Note: These are general guidelines. Always perform test welds to fine-tune settings for your specific application and equipment.
Maintenance and Storage
Proper maintenance and storage are crucial for preserving the quality and performance of low-hydrogen electrodes.
- Storage: Store Forney 42466 electrodes in a dry, sealed container or a heated electrode oven (rod oven) to prevent moisture absorption. Moisture can lead to hydrogen embrittlement and porosity in welds.
- Reconditioning: If electrodes have been exposed to moisture, they may need to be reconditioned in a baking oven according to manufacturer specifications (typically 700-800°F for 1-2 hours).
- Handling: Handle electrodes carefully to avoid damaging the flux coating.
Troubleshooting Common Issues
Here are some common issues encountered when welding with E7018 electrodes and their potential solutions:
| Issue | Possible Cause | Solution |
|---|---|---|
| Porosity (holes in weld) | Moisture in electrode, contaminated base metal, incorrect arc length. | Recondition electrodes, clean base metal, maintain short arc. |
| Arc Instability | Low amperage, poor ground connection, damp electrode. | Increase amperage, check ground, recondition electrode. |
| Slag Inclusion | Improper travel speed, insufficient cleaning between passes. | Adjust travel speed, thoroughly clean slag. |
| Undercut | Too high amperage, incorrect electrode angle, too fast travel speed. | Reduce amperage, adjust angle, slow down travel. |
Specifications
The Forney 42466 Low-Hydrogen Welding Electrode features the following specifications:
- Model Name: Forney 42466 Low-Hydrogen Welding Electrode, Mild Steel, 15" L
- Part Number: 42466
- Brand: Forney
- Material: Plastic (packaging), Steel (electrode core)
- Item Weight: 10 Pounds (approx. 4.5 kg)
- Item Dimensions (LxWxH): 15 x 6.5 x 6.25 inches (packaging)
- Electrode Length: 15 inches
- Suggested Users: Unisex-adult
- Manufacturer: Forney
- ASIN: B0772PLJ9W
- Date First Available: November 1, 2017
Warranty and Support
Forney products are manufactured to high standards. For specific warranty information regarding the Forney 42466 Low-Hydrogen Welding Electrode, please refer to the "Warranty" description provided with the product or visit the official Forney website.
For technical support, product inquiries, or assistance with troubleshooting, please contact Forney customer service directly.
You can visit the official Forney store on Amazon for more products and information: Forney Store.
