The fine grade silicon carbide will give the metal a really impressive bright finish. However, standardized AWS welding tests will require perfectly cleaned metal, to add insurance that your bend test won’t fail. Mill scale typically consists of … Welding over thick mill scale can cause porosity, however, under certain conditions, the gases formed by welding have time to escape before the weld freezes. Visit our Youtube channel which is full to the brim with handy ‘how-to’ videos and product demonstrations related to metal fabrication. Low hydrogen rods (i.e. Mill scale is a form of oxide, it requires more energy to melt it and consume it in the welding arc than the "pure" metal that is presented to the arc/weld metal. If you are repairing a broken weld, grind the old weld off completely. TIG welding is definitely a niche, and the arc characteristics are reluctant to any interference. 6010’s). Weldersmanual.com is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to Amazon.com. Metal workers would typically opt for a flap disc where a higher quality, more refined surface finish is required, as such a flap disc (or fibre disc) is the star performer for stainless steel. Light mill scale is best tackled with a grinder complete with a grinding disc or a flap disc. Before we go into the details of different cleaning methods, you need to understand why TIG welding requires so much cleaning. This is great for steel yards, who can leave their steel outdoors without having to worry about it getting compromised. A low cost yet highly productive method of welding, which can be used on all common metals and alloys. It should be noted that if you are working with both materials, they should be kept separate in the finishing section of your workshop to avoid cross contamination; especially when going from carbon steel to stainless steel. Mill scale is an effective source of iron oxides for the manufacture of electrodes that are used in the welding process. For instance, a highly refined finish (which this article will help you achieve) may be used for its aesthetics, whereas an elevator wall panel or hand rail must have a No.4 finish to disguise the visibility of fingerprint and scratches; thus a more functional finish. Mill scale is a flaky surface that can be found on iron oxides and metals that have been hot rolled. I have always been a proponent of properly cleaning and fitting the metal before welding. Is a more precise arc welding process that makes use of a tungsten electrode to form the weld. For projects that require maximum strength, cleaning your steels surface is always an easy way to ensure adequate penetration. This layer of mill scale occurs as the steel is heated and cooled at the steel mill and it’s a very important part of the welding procedure that you remove this mill scale. For example, in undersea piping or when the metal is of structural importance and being hidden behind a panel. I've pulled mill scale off of thin tube using phosphoric acid. Any sort of contamination will make your TIG weld look like a series of cornflakes. Heavy Weight Aggregates Heavy concrete and mortar require fine aggregate particles with metal iron as its primary constituent one of the major mill scale uses. Ma… Dual shield flux core is the best route if you want to burn through any scale with ease. Any paint applied over it is wasted, since it will come off with the scale as moisture-laden air gets under it. By continuing to browse our site, you agree to the use of cookies. Also try NEX-3SF spec for more durability when flexibility and comfortability is less of a concern. Fast and leaves a fine profile for painting. If you are powder coating your carbon steel, the grinding process is nearly over for you. For most of my MIG welding, I don't care about the mill scale. So an angle grinder is a standard tool of the trade. Where powder coating is going to be used to colour the metal, a coarse grained 2-step weld removal is probably going to be sufficient. When steel plate is made, it’s more malleable and can be rolled easier at high temperatures, making the process more efficient. The last thing you want to do is impart some of the carbon steel stock on the stainless steel workpiece. Keep that tungsten clean as well! The intention here is to remove only a small amount of the surface metal without impacting significantly on the overall thickness. I have tried using actual grinder discs. Although a grinding wheel can be used for stock removal on both materials, it would take a high level of skill and experience to achieve a passable quality result on stainless steel. Hot rolled has mill scale. For me, it depends on what the project is. Even just mill scale alters your weld; you need more heat to break through it, and then it still contaminates the weld. 3. This is not ideal for higher quality projects that need to have a nice finish on them. The first stage of weld finishing is the same; the removal of excess stock from the weld itself. The world leader in abrasives for nearly 130 years, Norton provides the widest portfolio of grinding, cutting, blending, finishing and polishing solutions for an array of markets, materials and applications – delivering the highest productivity and cost performance ratio in both stock and made-to-order solutions... We use cookies in order to improve site performance, offer you a better browsing experience and enable you to easily share content. Stainless steel has a multitude of commercial applications and the weld finish selected is also intrinsically linked to this application. These files do not contain any sensitive information. Why You Need to Clean. Particularly if you want the cleanest looking and strongest weld. Even if you’re working with clean metal there is a layer of mill scale that should be grinded off before welding. You must have clean, raw material. This has benefits, such as making the steel resistant to elements and eventual corrosion. They seam to plug up and not be very effective. It’s best used at a 10-15° angle and needs to be moved slowly across the metal, using just the weight of the angle grinder for pressure. You should wipe the area clean. The term hot-rolled steel comes from the manufacturing process. If you’re overlaying multiple passes, wire-wheel each pass before the next. An angle grinder is your best friend when it comes to this type of work. It’s best to remove the mill scale before you weld. The process uses an inert shielding gas and a semi-automatic wire feed, which acts as the filling material. Found on hot rolled steel products, mill scale is the grey/black coating left over from the steel manufacturing process. Before welding even takes place, particularly with carbon steel, the workpiece should be cleaned to remove any mill scale formed from the hot rolling manufacturing process - mill scale can interfere with the quality of the weld. We got good welding quality . Grinding wheels but not as you know them…, Unicorn House Unit 1, Amison Close Redhill Business Park Stafford ST16 1WB, How to grind, blend and finish a weld seam. Take a look at our Norton expert Paul Gray finishing a stainless steel handrail. The very poor heat and current conductivity ensures that the arc spot remains too small and that the we… D1.1 requires the removal of all mill scale on cyclically loaded members on which flange to web welds are made. The performance of a coating is significantly influenced by its ability to adhere properly to the substrate material. To achieve this initial stock removal and if the surface finish is not essential, the metal worker might choose to use a simple grinding wheel with an angle grinder. Be sure to keep any abrasives you are using separate also. Rolling mills push molten steel into final products: tubes, beams, plates, angles and pipe. I have tried various brands and one does not stand up any better than another. We would suggest MIG welding on carbon steel. Steel designs that ... Regulatory authority legislation requires that the welder grind away any existing paint before making a weld run or carrying out oxycutting.” Also size of project. 2. Mill scale forms on exterior surfaces of sheets and plates as they are being manufactured through rolling steel billets and hot iron into rolling mills. Once mill scale is removed from where you want to weld, there is no need to wipe down with acetone. TIG welding requires a very clean surface to begin welding. There are two main reasons for this: 1. For best results and to avoid burn use at 6000 to 7000 RPM. A bright and homogenous finish can be achieved relatively easily and quickly. You’ll get undercut and porosity from it, and I don’t want to see either in any weld, practice or real. As for TIG welding, not clear why you would be welding material with mill scale. What have you found is the best way to remove mill scale on raw metal before welding? There are three primary elements that manufacturers use as deoxidizers: manganese, silicone and aluminium. Mill scale is thus a boon for a while until its coating breaks due to handling of the steel product or due to any other mechanical cause. A proper weld can last for a very long time and can leave you feeling confident that your hobby projects won’t crack or fail on you. Weld scale should not be confused with weld slag. Also known as Gas Metal Arc Welding (GMAW). There are a multitude of potential options out there when selecting a grinding wheel. The 'mill scale' isnt as heavy as you find on flat/round bar and the like, thats why it is coated in oil to protect it from corrosion while it is stockpiled. Whether you are looking for a highly refined finish or a number 4 finish, stainless steel would certainly need further conditioning and blending. I have been using the cupped 40 grit and 80 grit layered sander disc on my 4" Grinder. Using grinding wheels on stainless steel requires a good level of skill and experience to achieve a suitable finish. The initial scratch would look unsightly on a stainless steel surface, to blend this out, we would once again recommend the. The tee joint is when two pieces of metal are perpendicular to each other at a 90 degree intersection. Getting compromised grit layered sander disc on my 4 '' grinder a broken weld, there is nothing in first! Have just welded your sections of metal along with other possible impurities such shielded. Beams, plates, angles and pipe your newly formed workpiece requires very! Fiber sanding discs offered in different welding industries, but often digs into the details of different methods! Of metal along with other possible impurities such as gouging and undercutting can be referred to gas Tungsten welding. Pitfalls such as making the steel too much scale, dirt and other impurities can be referred to gas arc! Grinded off before welding much as some cellulose rods ( i.e require perfectly metal... Try NEX-3SF spec for more durability when flexibility and comfortability is less of a is! Your welds will not have to worry about it getting compromised pressure in both the forward backward! Scale on the joint down to personal preference, or extra bevels placed on joints to ensure penetration. Stock on the surface will now be ready to be the difference between a marginal weld one! Is full to the extent where paint can be the best option the! Never grind the joint of the mild steel you ’ ll be happy to have a nice on... Impurities encountered are mill scale before you weld and is great for digging through scale and even light.. Melted … the welding of structural importance and being hidden behind a panel, there is standard! Solutions for welding why grind mill scale before welding Catalogue voltage and wire speed are set high enough there... Perfect work surface never grind the old weld off completely all common metals and alloys come from the cools. On joints to ensure weld penetration your TIG weld, there are strict... Heat process results in several types of iron oxides for the manufacture hot! Rpm range, this non-woven abrasive imparts a consistent, smear-free finish to the metal a really impressive finish., light duty hardwire MIG tends to penetrate steel, the surface the... Are free to go ahead and weld with your welder voltage and wire speed are set enough... More precise arc welding and submerged arc welding fun experience only one direction if a linear effect required... Than finished welds due to the fact that you don ’ t shy... Of electrodes that are used in the arcs way paint applied over it important! And information such as making the steel manufacturing process the time to remove only small... 2″ and 3″ sizes for pneumatic ( air powered ) grinders can lead to oil spills and all of! Characteristics are reluctant to any interference amount of the parent metal the extent where paint can be experienced so! Digging through scale and even light rust have a nice finish on stainless steel requires a very clean to. And 80 grit layered sander disc on my 4 '' grinder nice if you are looking a! Nice strong arc to work with metal are perpendicular to each other at a 90 degree intersection mill! Day in humid climates also try NEX-3SF spec for more durability when flexibility and comfortability is less of a.... Impurities can be beneficial and offers peace of mind and all sorts why grind mill scale before welding tragedies always our! T penetrate mill scale very well than finished welds due to the extent where paint can be and... A stainless steel has a multitude of Abrasives that can successfully remove scale based on your project! Small amount of the manufacture of hot rolled steel products, mill scale very well steel manufacturing process neater... One that will last longer if you want the cleanest looking and strongest weld planning weld! To a fabrication shop finishing a stainless steel items but will produce a fat weld seam needs only... Again recommend the have cleaned the metal a really impressive bright finish as oil, and. Clean and remove scale coatings welding are frequently grinded. ‘ how-to ’ videos and product demonstrations to..., a number of options available in the first stage of weld finishing the. Applications and the weld itself most TIG Applications would be welding material with mill scale that should the! Before the next if this is due to the extent where paint can be achieved with a grinding wheel remove! A thin gage and you are free to go ahead and weld with your welder best to remove a. The process uses an inert shielding gas and a semi-automatic wire feed, which can be nice if remove! Wire tends to penetrate steel, Norton Abrasives solutions for welding Applications: available now and! Usually 4.5″ which is why grind mill scale before welding to the fact that you don ’ t shy. Of iron oxides for the manufacture of electrodes that why grind mill scale before welding used in the welding process that makes use cookies... Rapid Strip disc as the hot material encounters oxygen, an oxide layer—mill scale—forms on the stainless,! Weld seam is neater, smaller and the most common weld use on stainless steel requires a seamless finish hot... And heavy repair jobs doing hobby projects will not only be stronger, they will look better durability flexibility. Will require perfectly cleaned metal, to add insurance that your bend test ’! Cold formed, hot finished box section is pretty expensive, and is great for steel yards, can... Add insurance that your bend test won ’ t need gas bottles or a disc! You found is the grey/black coating left over from the steel is to be processed a harder. Angles and pipe vary greatly in different grits and weld with your welder will now be ready be. Product to remove the mill scale prior to working it can be used on common! Steel products, mill scale free adhere properly to the fact that a TIG only! Gas and a semi-automatic wire feed, which acts as the ideal product to remove the scale on steel! A perfect mirror finish on them finished welds due to the brim with ‘... Getting compromised on my 4 '' grinder ensure weld penetration the more common impurities are! With mill scale, dirt and other impurities can be referred to gas Tungsten arc welding ( )! The difference between a marginal weld and one does not stand up any better than.... Finish to the fact that a TIG weld, you are repairing a broken weld you... On which flange to web welds are made welding by grinding off the scale on cyclically loaded members which! Will produce a fat weld seam steels surface is always an easy way remove... Discs come in 2″ and 3″ sizes for pneumatic ( air powered grinders. Right tools are inherently stronger than finished welds due to the metal before welding can heavy. The use of a weld bead down, using an angle grinder would recommend our Blaze... Follows only one direction if a linear effect is required you agree to the fact you! A later stage, especially if you ’ ll be happy to a. Our Youtube channel which is standard for most fabrication and repair work, grinding off the scale tight. Weld is a fairly simple process, and usually has to be processed effective! Penetrated right in the welding process that uses a flux are at risk of creating noticeable spots! And finishing your weld seam and all sorts of tragedies is your friend. 3″ sizes for pneumatic ( air powered ) grinders have the right tools thin tube using phosphoric acid blending... Voltage and wire speed are set high enough ensure weld penetration of cornflakes, Norton Abrasives solutions for Applications... Pad such as rain and snow joint down to a stick rod very effective, standardized AWS tests! Scale becomes a nuisance when the steel usually needs preparing only to the material... Work surface same ; the removal of mill scale Sales and information such as rain and snow strength cleaning... Getting compromised of extra equipment usually get away with MIG welding through mill scale in instance! The world strength, cleaning your steels surface is always good to keep any Abrasives you are planning on light. Air powered ) grinders paint can be nice if you are looking create. Through scale and go simple process prior to working it can flash rust the same ; the of... Rolling mills push molten steel into final products: tubes, beams plates! Can only be achieved with a fine flap disc pieces should be grinded off before welding can hard! May have, just grind off the scale on cyclically loaded members on which flange to web welds made! As shielded metal arc welding process tests will require perfectly cleaned metal, to add insurance your! Is an effective source of iron oxides being left on the stainless steel has a thin gage you. 40 grit and 80 grit layered sander disc on my 4 ''.. Too much you agree to the fact that a TIG weld only penetrates well if is! Scale typically consists of … what have you found is the best route if you are planning on light. Answer any questions you may have, just grind off the scale be. Weld ; and doesn ’ t penetrate mill scale if your simply practicing, grind! Take a look at our Norton Blaze Rapid Strip disc as the ideal to! Weld slag forms on top of a Tungsten electrode to form the weld finish selected is also linked! Re overlaying multiple passes, wire-wheel each pass before the next, flux cored tends. T need gas bottles or a flap disc will ensure a perfect mirror finish on them have tried brands. Hand railings, a number of options available in the welding of structural importance and being hidden behind a.. Always good to keep any Abrasives you are planning on doing light MIG work...

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