Need help, tips clogging!

admin

I am fairly green to welding.  I bought a Hobart 210 MVP about a year ago and have a lot of fun with it.  I don't have bottles so I am running flux core wire.  I am having tips get "clogged" and not sure what to do.  I can take a brand new tip and throw it in the gun and get maybe 3-4 minutes of weld time out of it before the wire starts having a tough time feeding, sputtering the wire, then eventually stops where I have to grab it with a pliers and give it a tug hitting the trigger to get it going again.  10 or so seconds of welding and it does the same thing.  I have tried everything I can think of.  I can clean the tip out with a torch tip cleaner and it helps but eventually does the same.  The wire I am using is .035 E71T-GS made by KT industries.  This stuff seems to smoke a lot, very dirty post weld but leaves a real pretty bead for me having such little experience.  Leaves a thick brown residue but it cleans rather easily.  I am suspect the wire is most of my problems and it seems to clog easier the hotter I weld.  What would be causing the tip to clog?  I can't see how anything would be able to get in and behind the tip and cause this.  Wire is clean and no rust as well.  Below are a few pics so you can see what I am dealing with.  The first pic was with a brand new tip installed and about 3 minutes of welding flat with my machine at settings tap 7 (max) and wire speed 50 with a 1/4" stickout max.  ALL MATERIAL WAS GROUND DOWN TO BRIGHT SHINY STEEL AS WELL!!What wire should I give a try (flux core) or do you think it's something else?Thanks for the help!This pic is what I was able to get out of the tip running the torch tip cleaner through the tip.  I have to really work the torch cleaner in and out before I can finally make it all the way through as well.  All of the carbon looking material is from roughly 3 minutes of welding in flat position.Nice looking weld but DIRTY!
Reply:Its not the wire that is your problem.  You are using the incorrect nozzle for flux core wire.  You are using a "gas shield" nozzle.  You need a "flux core"  nozzle for your specific gun and your problem is solved.  This is the nozzle you need when using "flux core" wire specifically.  Here's also a link to buy a couple:  http://www.calranch.com/nozzle-flux-cored Attached ImagesLast edited by SuperArc; 04-21-2013 at 02:18 PM.Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:Also use some anti- splatter gel or spray and keep a 1/2"or more stick out. Your using flux core so you don't have to worry about gas coverage.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:The guys above^^^^^got you covered, but that first picture was hillarious   weld looks good for f/c tho I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:OK, so, I've never experienced the clogging issue but judging from the pictures, are you saying these tips are for using gas shielded and the conical ones like the other picture are for flux core? Attached Images
Reply:Your voltage is way to high for that wire. I looked up kt industries wire on their website no information for running that wire.  I found out that if you want to run flux core wire you have to buy a quality product.  The wire i run is esab coreshield 15 same class of wire but the voltage range is only 15 to 17 volts for .035. Just take the nozzle off you don't need it.  Its causing you to run more than 3/8 stickout, i also found out that threaded tips can't carry the current, thats why I switched to benard center fire tips, one other possiablity is the mig gun does not have a high amp rating , my miller 211 only comes with a 100 amp mig gun gets way to hot for that ampreage actually started to melt the insulator, you have to remember that you have no gas giving you some cooling.  In my opinion get some better quality wire with information on how to use it and you will have better results.
Reply:Ok, lets go one step at a timeThe welding tips are the same for gas or flux core in most casesIf you are using argon you will use a torch setup like picture #1If you are using flux core you will use a torch setup like picture #2The flux core shield is to protect your torch diffuser (picture #3) from getting splatter on the threads and in the gas holesWhen flux core welding you can use as much stick out as you need, because there is no gas to cover the weld puddle. The flux in the wire (the smoke you get) acts as the cover gas and the flux coating helps in cooling and keeping out air that causes contamination just like in stick weldingI have run a stick out as far as a inch or more to get in hard to reach places. Attached Imageswww.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:You might check your polarity too... read your manual... as flux core is opposite polarity from solid wire / gas shielding.In my view, it's not your nozzle as I had a welder with only the gas nozzle and when using flux-core wire, I never got buildup like you showed.  OMG!Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:To reiterate..... 1). What I originally said2). What mechanic416 said3). What Rick V said about your polarity issue.  Mig (gas) welding uses DCEP, while Flux core uses DCEN.  You don't need to change wire brands or "tips."   Just the NOZZLE and make sure your polarity is connected properly. If its not, its a matter of switching two little wires in your machine.  Read your manual, it's in there.  Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:You don't need a nozzle with FCAW, the excessive splatter looks like an incorrect  ( too high) voltage problem. Pick up a roll of Hobart Fabshield 21-B, get your parameters dialed in 50-150 amps, 13-19 volts for .035 & you'll get very little if any splatter & nice beads.Last edited by Old Skool; 04-22-2013 at 10:16 AM.REAL TRUCKS DON'T HAVE SPARK PLUGS
Reply:As stated above your nozzle is not correct for flux core.I agree too with possible voltage concerns. I got the same clogging when learning overhead using MIG. My nozzle would clog EXACTLY like your's within a minute of welding. This of course would interfere with gas coverage, leading to porousity issues, god-what-a-mess. Took me several days to learn what was going on (class had no "theory"). Globular transfer doing overhead is just plain nuts! Reduced the voltage a fraction of a volt to get out of the globular transfer zone and into short circuiting and no more "nozzle issue". Keep this in mind if you are ever using gas and face such a "nozzle issue"XMT304 (school)SP125+ (home)HF 4x6 BandsawGood judgement comes from experience and much of that comes from bad judgement.
Reply:My humble, beginners advice is to look at the table inside your welders cover and match the piece dimensions you're working on with that table. That won't be dead-nuts but you'll be in the right field (even if it is "left field";-) Anyway, start there and then just make the small adjustments until you hear and see the right weld coming out. I'm fortunate enough to have a City Welding Inspector living 2-doors down who's helping me ALOT with my beginner welder stuff and he echoes most of the recommendations made here by guys like mechanic and others. I showed him your pics when he was leaving for work this morning and he said the same thing mechanic and the others said. He also said it's an easy beginner mistake. From my own profession, I can tell you it's like flying a helicopter. The sights, the sounds, the feel, it's all foreign and separate and you just can't even hold a 5' hover . You know everything to do but you know it separately and just can't put it together...until that one flash in time when it all just comes together. I'm finding welding to be the same way. With the right "instructors" like the people here and you asking smart questions like you do, it'll all come together. Just get the setup right.
Reply:Dedicated FCAW guns have no nozzle, it's not needed with the process. The mess the OP is getting is the result of either one or more of the following, voltage too high, WFS too high, excessive stick-out.We run flux-core by the pallet load & there's not a nozzle on any of the 4 guns !REAL TRUCKS DON'T HAVE SPARK PLUGS
Reply:Originally Posted by Old SkoolDedicated FCAW guns have no nozzle, it's not needed with the process. The mess the OP is getting is the result of either one or more of the following, voltage too high, WFS too high, excessive stick-out.We run flux-core by the pallet load & there's not a nozzle on any of the 4 guns !
Reply:I just looked at the owners manual, and the setting is right according to the chart.http://www.hobartwelders.com/om/6digit/o260274a_hob.pdfThe weld on the ball thingy looks good.  If the polarity was wrong, it wouldn't look very goodNever have seen that much crap on a tip"Any day above ground is a good day"http://www.farmersamm.com/
Reply:but you look at the other chart a few pages ahead of the inner door chart with the settings, and the voltage at 7 (220v) is pretty high  So................................If you're running too much voltage the wire will burn back into the tip, and fuse to the tip making it impossible for it to feed.  You did mention that you have to pull the wire out with pliers"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Here's the confusing part TO ME ANYHOW  This is from a 2005 Innershield catalog.  It shows what I know to be true from running this stuff.  The voltage max out is around 16vBUT!!  You go here http://www.lincolnelectric.com/asset...P/c3200010.pdf  And the max on .035 shows to be around 21v   And the feed speed is somewhere in the stratosphere I've run the equivalent of NR211 in the LN25 at the "old" recommended voltage, and it runs pretty good.  I go above the "old" voltage, and it runs like crap (however I did keep the feed at around 110-125imp).  Have to goose it up to the "new" parameters, and see how it runs, but somehow I think it's gonna run like crap.  But then again, I'm not a wire doodGood enough day to do some work in the "shop".  Run a few beads and take a look I guess."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by SuperArcEither your "dedicated" FC guns dont have small gas holes or even a "gas diffuser"  (for the GMAW process) further up the sleeve, or.... You don't care to ever use shielding gas with those "dedicated" FCAW guns and clogged diffusers are a mute point.   Gas Diffusers can and will get clogged over a rather short period of time when using FC wire.   Thats why a FCAW nozzle was invented to begin with!   To shield the diffuser from getting spatter, flux and other crap up in there.  I don't understand your logic.  By telling him not to worry about getting a "flux core" nozzle when welding with flux core, is akin to telling yourself not to use an a$$ gasket on a public toilet seat!  The purpose of a "flux core nozzle" is to PREVENT spatter and crap from clogging up the gas diffuser holes within his MIG gun!  Something I'm assuming your "dedicated" guns do not have, or.... you just don't ever use shielding gas with your mig guns and you don't care if the diffusers get crapped up.  If the OP ever wants to switch back to a shielding gas (GMAW), hes going to have a junked up difuuser and one messed up "mig" gun now, all because he took the advice from someone telling him that it wasn't needed.   Brilliant.Why wouldn't you use a nozzle specifically designed to keep all that crap out of the diffuser and majority of the tip itself????   They are inexpensive, easy to find and keeps the "innards" of the gun itself clean and debris free.  Keep telling the OP not to use a FCAW nozzle and his mig gun will continue to look and function like a plugged up "Cheveron" gas station toilet bowl.    "Nice one Clark..."
Reply:When I first started with flux I kept having that problem and it turned out to be me. I was holding the gun to far away and letting to much wire out. It cleared up nicely when I statrted bringing the gun down twords the metal more and keeping less wire out of the tip at once.PeteLast edited by Pallet Pete; 04-24-2013 at 08:15 PM.Hobart LX 235 Stickmate ( My new toy ) Jobsmart ( Buffalo Tools ) 125 Flux core welder. Yup she's cheap but lays a great bead.I heat with wood, weld, work on cars and brew beer. Life is good !Pete
Reply:Originally Posted by SuperArcIts not the wire that is your problem.  You are using the incorrect nozzle for flux core wire.  You are using a "gas shield" nozzle.  You need a "flux core"  nozzle for your specific gun and your problem is solved.  This is the nozzle you need when using "flux core" wire specifically.  Here's also a link to buy a couple:  http://www.calranch.com/nozzle-flux-cored
Reply:Originally Posted by mechanic416Also use some anti- splatter gel or spray and keep a 1/2"or more stick out. Your using flux core so you don't have to worry about gas coverage.
Reply:Originally Posted by weldermikeThe guys above^^^^^got you covered, but that first picture was hillarious   weld looks good for f/c tho
Reply:Originally Posted by jlamesOK, so, I've never experienced the clogging issue but judging from the pictures, are you saying these tips are for using gas shielded and the conical ones like the other picture are for flux core?
Reply:Originally Posted by Rick VYou might check your polarity too... read your manual... as flux core is opposite polarity from solid wire / gas shielding.In my view, it's not your nozzle as I had a welder with only the gas nozzle and when using flux-core wire, I never got buildup like you showed.  OMG!
Reply:Originally Posted by Old SkoolYou don't need a nozzle with FCAW, the excessive splatter looks like an incorrect  ( too high) voltage problem. Pick up a roll of Hobart Fabshield 21-B, get your parameters dialed in 50-150 amps, 13-19 volts for .035 & you'll get very little if any splatter & nice beads.Originally Posted by farmersammbut you look at the other chart a few pages ahead of the inner door chart with the settings, and the voltage at 7 (220v) is pretty high  So................................If you're running too much voltage the wire will burn back into the tip, and fuse to the tip making it impossible for it to feed.  You did mention that you have to pull the wire out with pliers
Reply:The soot from flux core is normal.  The splatter build up on the nozzle is contrary to my experience with flux core.  I get way more nozzle build up with 75/25 than with flux core.
Reply:Don't know if it helps but I had a crack in my front loader bucket on the John Deere and fixed it today with my 180HD Lincoln. It' taped and at 3/8" I set it at its max at "E" and 1.5 WS using .045 FC. I thought "Maybe"; Deere makes some tough steel. I had to fire-wait a bit but the puddle formed really easily and, going slowly, I had no problem with the weld seeing the penetration on the other side. Proper stand-up and even good waves so, I don't know Hobart but it should be doable for you. I was even using the stock plastic nozzle.(Would really like a copper/brass one) For me, it was all about waiting on the weld puddle and then pulling it along. I bevel "V"d the crack but other than that, nothing special. I wish you the best of luck
Reply:Originally Posted by ProCharger..............................I guess I really need to change the title to the thread.  I could care less about the buildup, I think people are referring to that as the clog.  That might be part of the problem I am having, I don't know, but the real problem is the wire becomes unable to feed through the tip due to the INTERIOR of the tip getting the black carbon soot buildup.  It's not getting fused to the tip and I have plenty of stickout to give it a small tug to get it going again but it does the same almost immediately.  When this happens it builds up to the point of stoppage, not just an immediate stoppage.  I can "feel" the wire getting slower as it will sputter coming out instead of a steady feed.....basically pulsing and then it gets to the point where the wire just stops.  That is probably a better explanation of what is happening.  Any tighter tension on the feed roller will just start curling the wire without the tug from the pliers.Thanks for all of the replies.
Reply:Originally Posted by Old SkoolThe fact that you don't know that a dedicated flux core gun has neither a diffuser or nozzle leads me to wonder if you actually know anything about the process or if you're just another internet smart-***.As far as using a standard mig gun minus the nozzle dial in your settings & learn how to weld & you can weld all day with NO splatter or damage to the gas diffuser now go back to your little bench & make a lawn ornament or something !
Reply:Hoo boy, this could wind up being as stimulating as the wife's roller derby games,  I know I'm stickin' around!!  --  Looks like crap flux core wire. Try your set up with Lincoln or Hobart wire, might be the solution. I picked up a couple of 2 lb rolls of chinese flux core from princess auto, Canada's HF and I wound up with more spatter than weld, looked a lot like those welds of yours, really sooty with ok looking welds. I'm certain that china makes that garbage specifically for the North American market just to f us up. Your best bet however, is to get gas for superior welds.Last edited by bearston; 04-29-2013 at 04:20 PM.When a welder tells you to "stick it", what do they really mean?"In a time of universal deceit, telling the truth is a revolutionary act." - George Orwell