.045 Mod on 100 series Spolgun quit working
Tue, 31 Aug 2021 10:13:15 GMT
Hello, I took the advice of others on this site and drilled and re-tapped the barrel of my 100 Miller Series Spoolgun. It now accepts the same tips as my (M-100?) mig gun. Anyway, I'm using it with my MM211 welder. I put everything back together (MM211, 100 Series Spoolgun w/ M100 .045 tips, Radnor 4043 3/64" wire). I did a couple short welds on some thick 6061 aluminum and seemed to be getting good welds with the voltage maxxed out and wire speed set at half. The first real test weld was darn near perfect. It felt good from beginning to end and the settings seemed to be perfect. I set up for more test welds after that and that's when everything went south. Welds immediately would burn back and wreck the tip. I played with the settings and just ended up burning up more tips. So then I tried just pulling the trigger and ran wire through it without actually welding. It will push wire as expected, but if I add a little resistance by squeezing the wire as it exits the gun it starts slipping at the drive rolls. The drive rolls put a fair amount of knurl on the wire as it passes through and I think it may be dragging slightly on the liner or the .045 tip. I did put an .035 tip and wire back on and my welding abilities went back to normal.Thoughts? What's going on? I'm using the original liner. Can I get a bigger liner in there? The wire is 3/64" (.047) and I'm using .045 tips. Could that be the problem? That first pass was just so nice... I'd like to get back there again.Good luck -jim
Reply:have you adjusted the drive role tension if possible? Is the tension to tight squeezing the wire so it hangs up in the tips when the tip of your gun gets hot???Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo. Hand tools, power tools, welding and cutting tools.
Reply:Tips for welding aluminum have a larger hole, you will need something like .062 hole because aluminum expands more than steel.
Reply:Ok, so I drilled out a tip oversize and it helped temporarily. What seems to be happening is that the drive rolls are creating small knurls on the wire and the hole at the base of the base of the barrel where the wire enters is maybe a bit too small and starts shaving off the knurls a bit and I start getting buildup around the wire causing even more drag. I'll keep working on it.good luck -jim
Reply:Try reducing the drive roll tension so the knurling is barely on the wire. The tension maybe too much and making the aluminum wire oval with large knurls.Everlast PowerPro 256, Everlast W300 Cooler, Everlast Cart 250Millermatic 211, Spoolgun 100, Miller HD CartJackson W60 Truesight Digital Auto Darkening, Victor 315 Torch sitting on a Harper 830-86 cart
Reply:You just need the right tips made for Aluminum wire, they make them. Regular .052" tips will do in a pinch but .062 are way to big.A few weldersA lot of hammersA whole lot of C-clamps
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