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Flux Core 18 gauge - Troubleshooting


Wed, 27 Oct 2021 07:51:16 GMT
Hey, it's been a long while! Hope everyone is doing well.After ages without welding anything, I took the dust out of my Flux Core machine to try some body work on my car after being scammed on a repair I paid for.Before I took that long hiatus, I had made some tests with maybe a 16 or 18 gauge sheet, where I cut a square out and welded it back in place, and it went kind of smooth back then. Might have some picture in an old post here, it was not perfect but for sure decent. Right now though, I'm working on my car and the welds are being difficult as hell. It's hard to make consistent welds, it will often burn through, sometimes it will splatter and sometimes it will do OK. At first I thought the reason was me not having practiced in so long, but then I started noticing some things that could be making my life harder:The Flux Core wire rusted a little from the time it was kept in storage. It was maybe stucking into the gun contact tip sometimes and not feeding reliablyI noticed just today that the grounding cable was very damaged on its connection with the clamp (picture below)Right now I removed the exposed wire, using the one that was lower in the roll thus less exposed and rusty. Still not ideal for sure but honestly, if I were to replace the wire completely I'd probably want to clean the gun liner as well since small pieces of rust might be trapped in there. So I'm trying to troubleshoot with the wire I got first before I buy new wire and have to do all that work. I also cleaned the internal parts of the welding machine feeder (without using any oil on parts that touch the wire ofc) and replaced the gun contact tip leaving the one I was using before soaked in kerosene to clean it up so I can use it in the future.After doing that I was still having some trouble today finding the right settings and reliably spot welding the butt joint, and found out that my grounding cable was very damaged where it connects to the clamp:
Flux Core 18 gauge - Troubleshooting
I bought a 35mm eyelet terminal (went for a bigger one because it's not labelled 80amps like the eyelet I have on the clamp) and am planning to cut the wire short and remake the connection, maybe even filling the eyelet with tin/lead soldering after crimping.Does it sound like that ground clamp is the cause of all this difficulty with the welding? Is it fine using regular 35mm steel eyelet terminals for connecting the cable to the clamp?Thanks in advance!

Reply:Ground and ground connection is a good start.  Check internal connections by removing and sanding. Your rusty wire flux could be compromised from moisture.  There could be grabbing. Happening in the liner too.
Reply:
Flux Core 18 gauge - Troubleshooting
Originally Posted by tapwelder
Flux Core 18 gauge - Troubleshooting
Ground and ground connection is a good start.  Check internal connections by removing and sanding. Your rusty wire flux could be compromised from moisture.  There could be grabbing. Happening in the liner too.
Reply:Hi  18 gauge  with fluxcore wire  is very challenging   I could never get it to work.   It would be a whole lot easier     and  a tidier   job  if you could switch to mig wire  and   C /25  gas.
Reply:
Flux Core 18 gauge - Troubleshooting
Originally Posted by Josey
Flux Core 18 gauge - Troubleshooting
Hi  18 gauge  with fluxcore wire  is very challenging   I could never get it to work.   It would be a whole lot easier     and  a tidier   job  if you could switch to mig wire  and   C /25  gas.

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