Weld Bead Removal

Welding joins two pieces of metal by heating the metals until they become molten and fuse together. The addition of metal filler is added at the same time to completely join the two parent metals and strengthen the joint. Together, these three liquid metals form a welding bead, as noted by Jay Storer in "The Haynes Welding Manual." Sometimes this process is done incorrectly, requiring that the bead be removed and redone to produce a neat and clean final product. This removal process is straightforward and requires a few tools to do properly.

Welding apron or jacket
Face shield
Work gloves
Grinder
Grinding disk
Clamps
Wire wheel
Wire brush

Instructions

- 1
  Install a grinding disk on the grinder according to the manufacturer's instructions. Assure that the disk is secure by steadying the grinder and holding the locking button down with one gloved hand as you attempt to turn the disk with the other hand. If the disk doesn't move, it is installed properly.
- 2
  Use clamps to secure the welded item to the work table at a comfortable angle that allows you to reach the bead area you want to remove. Test to make sure that the metal is firmly clamped down and that the clamps do not inhibit you from getting tools into the beaded area.
- 3
  Start the grinder and hold the tip of the grinding disk along the area you want to remove, making sure to keep the disk straight as you make your way through to the end. Do a shallow pass along the length of the bead to create a straight path and then follow the path from one end to the other until you have ground out the beaded area completely.
- 4
  Check the area for jagged edges and other imperfections. Retouch them with the grinder, making them as straight and clean as possible. Clean any remaining debris with a wire brush or grinder with a wire wheel.

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