MIG welding frustration

[BarnyardEngineering]

As i already said - try setting for 1/4 inch. Tell the machine you are running 035 wire. i run 035 wire only. Er70s6. Just finished a roll today. Went to change and realized i had used a roll from harbor freight. Replaced with a roll from hobart. Went right back to welding. No difference in welds.

As I already said, there isn't a 1/4" setting for .030 wire.

As I've already said, I've tried the 1/4" setting for .035 wire. The wire instantly vaporizes back into the tip, and ruins the tip.

My first two 10lb rolls of wire were .035, and the results were no different. I thought maybe the thinner wire would be better, but it's the same.

 

[BarnyardEngineering]

"High gas flow?" The chart on the welder says 50 SCFM and I've already reduced it to 30. You're saying I need to go more?

 

[DanielW]

As I already said, there isn't a 1/4" setting for .030 wire.

As I've already said, I've tried the 1/4" setting for .035 wire. The wire instantly vaporizes back into the tip, and ruins the tip.

My first two 10lb rolls of wire were .035, and the results were no different. I thought maybe the thinner wire would be better, but it's the same.

There's surely a way to manually adjust voltage and wire speed like any conventional MIG welder, no? Don't know about Lincoln, but on newer Millers with the fancy screens, the settings they give you for 1/4", etc. are just a starting point, from which you can tweak as desired.

This is why I went for the Cenury 260 when I decided to buy a new MIG machine a couple of years ago. Made by Lincoln, and pretty much the exact same simple, two-knob transformer machine they made under the 'Lincoln' name until they decided to get all fancy with computers, screens, etc.

 

[stevieb49829]

"High gas flow?" The chart on the welder says 50 SCFM and I've already reduced it to 30. You're saying I need to go more?

I think you need to give up on the pre-programming. It obviously is not working with you and that machine. That may mean the machine has a problem. There is some very good advice coming to you (not necessarily from me) and you should probably set the machine up manually (if it allows that) and try some experiments. But change one parameter at a time, all the way up and down the scale. It sounds like you've tried that, but the machine is overriding your manual inputs. Which tells me the machine is not working correctly. Take it back to your dealer, and make them prove to you that the machine is OK, and that it's not just a loose nut behind the wheel.

The way to tell if the gas flow is adequate, but not too much is to try a weld without it. It should be full of bubbles and porosity. Then turn the gas on at a very low flow, and strike some welds as you periodically increase gas flow. When you get a good sizzle sound and the weld is sticking good at the edges of the bead, the flow is good. It may be that your regulator is lying to you. 50 seems extremely high to me. I'm running my Lincoln 170 SP at 18 to 20, same gas as you are using. It will weld at higher flows, but that's just wasting gas. Another thing you could try, but might be expensive, is to try using a tri-mix. It has helium in it, and I use it for stainless. It welds hotter because of the helium. If you are close to the end of a bottle, try it. It's more expensive, but it really welds nice, even on mild steel. steve

 

[joeysmith]

Something i haven't noticed mentioned that maybe I missed
What about power to the machine?
Is it a good heavy circuit?
Have noticed it makes a big difference on performance

 

[redtom]

I have a 210 i bought about 3 yrs ago. I was on here with issues also welding thin metal on a vehicle restoration. I had some welding classes although it was in trade college in the 80's. I think one main issue is running the machine on 220v. I only use 220. I know it's rated for both but I think it matters. The welding shop where I bought it also warned about amp service and size and length of extension cord. Im far from an expert and my issue was getting good welds on thin with .023 wire. I've since all but given up on 023 and use 035 for all work, even real thin. Ive never used 030. I messed with all the settings...run in, etc. My welder seems to love 10ga on up. I only use solid with 75/25. I feel that the pre settings are a bit cool and usually use a setting one gauge thicker than what im welding. Once in a while it's a "stubbing SOB" which i don't quite understand. Like I said im no expert and my welds would never pass any tests and I have good ones and bad ones. I grind a lot.

 

[moresmoke]

I am assuming you’ve been through more than one bottle of gas in all this. The results you are describing sound kinda like running straight argon.

Straight CO2 will burn hotter, but make more spatter.

 

[drsportster]

...and because I knew you'd want a picture, I went out and did my best...

This is the 3/16" program on 3/16" mild steel. First bead is push left-right. Second bead is straight pull right-left. Third bead is backwards cursive e's from right to left.

View attachment 128159

What is wrong with that ?

 

[drsportster]

Use the chart inside the cover