I'm working on tacking a 1/8" bar to some small (1/2" o.d.) square tube (tee joint). Knowing how thin that stuff is, I bought a small piece that I cut up and I've been practicing on it.
Initially I started out with 3/32" 6013, running at about 70 amps and made a decent weld, but the second time I tried it I dug an enormous hole in the tube. I tried backing the heat down, but I can't keep the arc going much below 60, which is probably still too hot. I tried some 1/16" 6013, which seemed like a good plan around 40A. I've been pretty successful at not blowing a hole in the material this way, but after chipping off the slag I found the bead fused to the sq tube and the bar, but did not join them. I had to laugh, because the slag was the only thing holding the part in place . I noticed that Jody C said in one of his videos that lack of fusion is common with the 6013 ... I think it probably had more to do with the weldor .
Any tips here? I'm thinking about picking up some 1/16" 6011 to see if I can do a better job with it. Would rod angle help? I'm trying to point the rod down into the heavier bar stock to direct the heat there, between 60 and 70 degrees.