When making a fillet weld, the electrode should be aimed at the base metal and the welding gun held at what travel angle?

• A. 30°
• B. 60°
• C. 70°
• D. 90°

Answer: (C)

In fillet welding with a GMAW process, the travel angle controls where the molten pool forms and how the heat is distributed between the two pieces being joined. Aiming the electrode at the base metal helps the arc fuse both legs of the joint, creating a strong, well-formed fillet. Holding the gun at about 70 degrees to the work places the arc so heat is directed into both pieces and the molten metal is deposited along the corner, giving a good bead with proper throat thickness. If the angle is too small, the heat tends to favor one leg and you can get underfill or an uneven bead. A larger angle, like 60 degrees, is less optimal for balanced fusion in this scenario, and a 90-degree angle makes it hard to control the arc and the pool, risking poor fusion or a rough bead.