Hello billk63, look at the specifications on Lincoln's site for this wire, you'll notice that it is listed with a max. thickness of 3/4". Generally this is indicative of issues that come up from running pass after pass over the preceding filler metal without having the proper tempering elements/additives in the wire's core make-up. You should consider using a more suitable wire and make sure to stay within the operating parameters of that wire as well. NR 212 is considered a general purpose wire with limited thickness application and although it is likely wonderful to run, it doesn't have the necessary characteristics to qualify on the D1.1 structural test. NR 232, NR 233, Coreshield 8, and other such wires "will" make that test when properly set-up and run. Good luck and regards, Allan
Ladies and Gentlemen,
Look at a lot of bend straps for A36. The failure mode is something I have not seen. You left out "Innershield® NR®-212 - Lincoln Electric www.lincolnelectric.com/.../product.aspx?...212(Lincoln... Lincoln Electric Innershield® NR®-212 from Lincoln Electric is recommended for single or multiple pass welding on up to 19 mm (3/4 in.) thicknesses" FCAW (G). Start point it is not for 1 inch plate. If you call Lincoln they would say more. The other aspects are numerous. The wire might have been from different batch or wax used to get it through the contact shoe. The "failure" looks near "brittle". Been an engineer and into welding for plus 20 years / five patents.
Sincerely
Len Andersen weld@spemail.org
914-536-7101
www.lenandersen.com
PS - I am looking for a job !
Just a thought here, but I'm wondering if the heat generated when the backing bar was cut off, has anything to do with this problem. I noticed the heat bluing where the break is widest.