Wire keeps on clogging up

Tue, 31 Aug 2021 13:59:45 GMT

go to see Welding Machine for Wire keeps on clogging up

My wire keeps on clogging up with material as I weld. What is the thing called the brass piece? Well the wire jams up with metal everytime I weld.I tried a faster wire speed but didn't work..I am laying good welds by the way though just it clogs up.I am using e7 wire with .035"  with c02/argon mix.
Reply:Maybe I am misinterpreting what you're saying... like the wire is sticking to the contact tip?  Brass piece... nozzle?Could be spatter splashing back and plugging off the nozzle.  I'll get too close with mine ( I run 0.23 and CO2 ) and get a glob of molten metal that will stick to the contact tip and the wire, causing it to stick and spit and sputter...
Reply:I'm still trying to figure out what you're talking about with wire clogging up.  I'm going take a wild guess and say that either your wire speed is too high or the voltage is too low cause I kinda get the feeling that you're spattering wire everywhere and not welding much cause the wire's not melting smoothly into the weld pool.  I could be completely wrong though, as I really don't understand your question.The skinny copper thing with the tiny hole down the center of it that the wire travels out the end of is the Contact Tip.The large copper or brass tubular looking thing at the end of the gun that covers the contact tip is called the nozzle.  It directs the gas over the weld.If  you have alot of spatter getting up in between the nozzle and the contact tip, take the nozzle off and gently ream out the garbage with your mig pliers or a screwdriver or anything else you have that will fit in there and dislodge the slag.  Then clean off the outside of your contact tip and inspect the end of the hole the wire comes out through.  If it's all deformed, replace the tip with a new one so your wire can slide out smoothly.Are you sure the gas is on and the regulator set to 20 to 30 cubic feet per hour?Also, clean off any paint, grease, etc from the metal in the area of the weld before you make your weld.  You'll have alot less mess if the metal is clean.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Yes, the contact tip is getting clogged up with splatter. I might of had the voltage to low. I had it on "3" and I was doing 3/8" thick metal. I only had it on "3" cause I was doing it on 110v....
Reply:I have never used a DVI2, but you have to select your voltage for the material you are welding, not by the current you are plugged into.I'll try to illustrate using voltage numbers:If you are doing a weld that requires 28.5Volts and 550 IPM using 220V input, you cannot set it to 23.5V and 250 IPM just because you are plugged into 110V input.  Set your machine for the material, and get after it.  Without having a manual, I do not know if your machine will:A) Not weld that "hot" on lower voltage input. B) Weld at that output with a lower duty cycle.Read your manual carefully first, then give it a try. Sounds like you are way too cold for the wire feed and throwing spatter everywhere as previously mentioned.  If your machines settings are correct for the weld being done, your electrode stickout is correct, and your travel speed is correct, you should be able to weld a LONG time in Short Circuit, or Spray Arc Transfer before spatter becomes an issue.  Globular Transfer just makes a mess, I don't care who you are.Later,Jason
Reply:alrighty- gun parts starting at the front:copper tip, brass gas diffuser, insulator, copper or brass nozzle, gun tube (gooseneck), handle.If the wire keeps popping back to the tip and you have to keep tightening down the tension arm, your liner (choke cable looking thing running up the center of the gun) needs to be replaced.I hope this helps.
Reply:I might have it going again... I was welding 3/8 on 110v and I doubt I got it hot enough.. I step down to 1/8" metal and it is welding MUCH better.
ReplyOL, crazy Pyro!   110v is just not enough juice to do anything more than 1/4", if that, at least in my limited experience running on 110 anyways. Glad u figured it out!MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Originally Posted by DesertRider33LOL, crazy Pyro!   110v is just not enough juice to do anything more than 1/4", if that, at least in my limited experience running on 110 anyways. Glad u figured it out!
Reply:There's also some stuff you can buy called 'mig dip' or anti splatter in spray cans. I would get the spray cans, if you put a bit on the end of your gun between the nozzle/tip it should help w/ the berries if you have to weld something that's going to splatter.I have a metal weld table that i HATE to clean the 'berries' off of, so i just hit it w/ a quick spray and that'll keep the metal from sticking to the top.