MIG wire debate, harbor freight or specialty welding???

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I'm a newbie here on the forum, but have been welding on and off for about 15 years, so please be gentle.  LOL!I have a Millermatic 140 MIG Welder Auto-Set welder that I have been using for the past few years with great luck, recently my welds have gone to **** and it's pissing me off.  With the auto-set how the hell can be so ugly??? HA HA!That being said I am running C25 from Praxair right around 15CFM +/- depending on outside conditions.  I live in Phoenix so we don't get much wind, when we do I turn up the shielding gas a bit.  My wire is .030 wire.This brings me to my question, the wire I am using in the welder is Harbor Freight Solid welding wire.  As a novice I don't really know the difference so I am here asking the obvious question.  Will my weld quality improve with another wire that I can get from a specialty welding supply shop, or does the wire not make that much difference and it's just the welder messing it up?  The welds looked like they had "pitting" in them, kinda like their was too much heat going on there.  The auto-set feature was set for the proper thickness of metal and wire diameter too (fwiw).Until the past few weeks my welds have been great, with some quick fixerup welding i was doing this weekend the welds looked like hammered horse **** and make me really think about "cheep crap" i have in my welder.Any advice would be appreciated.
Reply:What wire have you been using up till now? Have you always been using the HF wire? If this is your first spool of HF wire, go get a spool of Lincoln or Hobart wire and try it again. If the welds improve, go back to the HF wire and see what happens. I think you will have then answered your own question. The HF wire may be ok if you want to temporarily TIE something together, but not for getting Quality Welds, like you are wanting. I don't buy their welding rods either for the same reason.
Reply:You may be right on there, the wire isn't bad, but it just doesn't seem to be up to my standard.  The welder is capable of much better quality welds than it's been delivering lately... who know it could be me partially as well, oh yea and my crappy welding helmet (which is being replaced with a nice miller one very soon).
Reply:Like any wire, some machines perform better with different brands. The Italian wire works well in the machines I own. or owned. In fact my C-300 Powerwave welded nicer with HF .035 solid wire then any L-56. My little Esab 200, and Miller Shopmate/Thermal-arc 400 MST all welded nice with the INE wire. Probably better then any China/ Hobart HB-28 out now too. I generally like Esab Spoolarc 86 about the best, but the HF works very well too.http://ine.it/mig_mag_wires.aspLast edited by Brand X; 02-10-2014 at 01:50 PM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:What wire have you been using up until now? Is this the first spool of HF wire?
Reply:I have been using HF wire, still the same 10# spool that I stuck in the machine when I got it from a friend.  It's been pretty decent, but I think my welds could be better which is getting me thinking about perhaps the wire quality isn't there.
Reply:Thanks for the info Brand X, i appreciate it.  I am going to look into maybe picking up a couple 1-2# spools of various wires and doing some experimentation on identical welds and looking at quality of the welds.
Reply:the pitting with the MM140 sounds more like a shielding gas issue than a wire issue.  did you get a new tank or change something on you gas system?Multimatic 200Ellis 1800Haberle S225 9" cold sawMM 300;  Spoolmate 30A w/ WC-24TB 302GDynasty 280 DX Tigrunner
Reply:I got a new tank from Airgas on Thursday, it was labeled as C25 and painted brown.  Never had a mislabeled bottle from them, but it's possible perhaps????I don't really know if "calling" it pitting is right, the welds just look like **** to be honest which made me call into question multiple things the top of the list being the wire.  I think later tonight I am going to get out some 1/8" steel and do a few test welds on that to see, perhaps the metal i was using caused some issues too.  The metal was an unknown grade of steel as I was doing a "repair".
Reply:Check the conditions inside your nozzle. If the shield gas doesn't flow smoothly, it's worse than no gas at all.Also check you hoses and regulator for proper operation.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:tackit, the metal was 1/8" and within the specs of the welder.  I only use brake parts cleaner to clean anything, it leaves no reside at all.  This is coming from my gunsmithing experiences.  You might be right as well about giving up the heat to the steel it's a good point.mike, you also mentioned a good point about the gas.  I need to look inside the nozzle as well and insure it's clean, and flowing.thanks for everyones input so far!
Reply:Check the tension on the drive rolls and spool hub- I've found that as the 10lb spools need adjustments towards the end of the spool- at least that's how it was on my little lincoln.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Please stop using brake cleaner.   Check out the topic below. http://weldingweb.com/vbb/showthread.php...=brake+cleanerMultimatic 200Ellis 1800Haberle S225 9" cold sawMM 300;  Spoolmate 30A w/ WC-24TB 302GDynasty 280 DX Tigrunner
Reply:Did you overheat the inductor and transformer in your machine? Been switching to flux wire and have polarity mixed up maybe?I have tried a few different brands of solid wire and i have found the one that lays down the best welds is also easy to find almost every where, Lincoln wire.old Miller spectrum 625 Lincoln SP-135 T, CO2+0.025 wireMiller model 250 and WP-18V torchCraftsman 100amp AC/DC and WP-17V torchCentury 115-004 HF arc stabilizerHome made 4 transformer spot welderHome made alternator welder
Reply:Another thing that will cause crap looking welds is mill scale.
Reply:AGAIN< http://weldingweb.com/vbb/showthread.php...=brake+cleanerREMINDER on what Drooopy posted, read this !!!!!Maybe try .024 wire in the 140 might run smother. I like the Lincoln Super Arc L 56 .030 for my Miller 211. I don't see any savings buying the HF stuff.
Reply:Originally Posted by DrooopyPlease stop using brake cleaner.   Check out the topic below. http://weldingweb.com/vbb/showthread.php...=brake+cleaner
Reply:Originally Posted by BD1AGAIN< http://weldingweb.com/vbb/showthread.php...=brake+cleanerREMINDER on what Drooopy posted, read this !!!!!Maybe try .024 wire in the 140 might run smother. I like the Lincoln Super Arc L 56 .030 for my Miller 211. I don't see any savings buying the HF stuff.
Reply:Originally Posted by mad welder 4Did you overheat the inductor and transformer in your machine? Been switching to flux wire and have polarity mixed up maybe?I have tried a few different brands of solid wire and i have found the one that lays down the best welds is also easy to find almost every where, Lincoln wire.
Reply:Originally Posted by rszkutakYa know when I got the welder I tried .024 wire and .030 wire both with the same gas.  The metals that I weld tend to be 16 gauge (lightest) up to 3/16" (generally max).  I used both .024 and .030 on the metals and found that .030 welded better in my applications than .024.  I have 2# spools of the .024 in the cart, but save that for thinner metals which i do pretty infrequently.It's very possible that the tension issue could also be my problem too, I've had that same spool now for a couple years and laid a ton of beads so i could be low on wire there.I ordered up INEFIL ER70S-6 .030-Inch on 10-Pound Spool Carbon Steel Mig Solid Welding Wire off amazon today (amazon is in south phoenix, so it's next day delivery no matter how slow "free shipping" is, for $27.99 I couldn't complain.One thing that jogged my memory about the welding this weekend was that I watched the wire when it was laying down beads, it seemed that the wire didn't fuse evenly and it tended to "melt" a bit further up the lead than was touching the metal, kinda like the speed wasn't fast enough....  I'm sure that doesn't make much sense but i'm trying to describe it and it's difficult.
Reply:I run Home Depot / Lincoln wire in the Multimatic and Hobart in the 350.  No problems with the Lincoln wire so far.  As far as I know it is ER70s-6 equivalent.  The -6 means its higher in silcon and yes, you see slight brownish flakes of silicon on top of the bead.  The Lincoln wire seems to be pretty consistent from purchase to purchase (OK, I've only bought 2 spools so far - so I'm no expert).  Being available at Home Depot makes it available in 99% of the country - as for pricing, who knows, but I do know I can buy wire 9:00pm on a Saturday.Gas flow.  I use more than 15.  15 is what I use for TIG welding.   25 cfh (on some regulators there are multiple scales, make sure you are reading the right one.   I go as high as 35.  I have no scientific testing on what works and what doesn't.  I guess at it.  25 for inside corner - where gas gets trapped, and 35 for outside corner, where gas goes all over the place.  Make sure your nozzle is clean.  It can make a big difference, blocking gas to one small area of the puddle.Wire feed.  Lets just say that I used to set minimum pressure on the pinch rollers.  Till I figured out (duh!) that the amount of push needed to drive wire along a prerfectly straight gun is different than if the wire liner had a few sharp bends in it.  I test the wire drive by grabbing the wire with gloved hand and seeing how much tension I have to add before the wire slows down.  I actually don't slow the wire down, just more or less make sure the machine will push through, without slipage, against some moderate blockage (or whatever).   Nothing like welding a plate to the floor of a car and wondering why one side had a nice arc and the other side didn't....  it was because I twisted the gun to do the other side.Autoset also assumes a consistent wire size.  You might, just for kicks, measure the wire's actual thickness in a couple places.Finally, check your polarity (is the wire + or -) and make sure your work cable/clamp are in reasonable condition.Oh, and when in doubt, try adding more wire speed.  Take the chart on the door and set machine yourself.  I can't speak for the 140, but with the multimatic, Miller did an excellent job (at least on the moderate to thicker wires - a little off on thin, 22 gauge and thinner stuff - runs way too hot).Con Fuse!Miller Dynasty 350Millermatic 350P-Spoolmatic 30AMiller Multimatic 200Hypertherm PowerMax 1000G3Miller Maxstar 200DX
Reply:Originally Posted by rszkutaktackit, the metal was 1/8" and within the specs of the welder.  I only use brake parts cleaner to clean anything,    it leaves no reside at all.  This is coming from my gunsmithing experiences.  You might be right as well about giving up the heat to the steel it's a good point.mike, you also mentioned a good point about the gas.  I need to look inside the nozzle as well and insure it's clean, and flowing.thanks for everyones input so far!
Reply:Originally Posted by pepiMight want to rethink that one for your own self, and definitely stop giving new welders that bad advice. ACETONE safer and is the preferred cleaner.
Reply:If you have porosity suspect incorrect gas coverage first off because its the leading cause in most of my cases. First check your lead where it fastens into the machine. Loosen the wing nut and remove the lead. Clean the contact area and inspect the o-ring for issues. Lube the O-ring with a dab of pure silicon grease and reinsert the lead, tighten wing nut ensuring the lead is butted up all the way in the machine. Clean the end of your mig gun with a wire brush ensuring all the gas holes are clear. Turn the bottle on and soap down all the connections because a leak on the low pressure side can draw in air and contaminate the weld area. That's where i would start. I'm just a hobbyist/farmer/firefighter. Just saying............Good luck...........Fireman BillHH 210 MVPMM 211 Spoolmate 100Lotas LTP5000D PlasmaOxy/Accet (Victor)Wards AC/DC buzz box30 ton old hyd pressA few brand name toolsA bunch of cheap toolsA wife to worry me and4 dogs to supervise me
Reply:My thought is first change the tip. Also u said the spool is a bit old so maybe rust/contamination/moisture on the spool of wire or dirty liner.Try changing tip and blow out liner. then change out to a small 2lb spool to test. That will rule out a machine malfunction. Your polarity is correct right?I run Hobart wire when I have time to order online or my LWS has some in stock at good price. I have also run cheap Forney wire from local hardware store, although the "cheap" forney is actually more expensive then the good stuff i can order online even after paying shipping. Never ran HF stuff but hear its crap but my friend has ran it in his Campbell-Hausfield unit and has no complaints but he has never ran the "good" stuff either.HH140---------------------------https://www.facebook.com/brandon.pike.9