Problem with Consistent MIG Welds

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Hello.  Another newbie here with little experience with welding and have some general questions about MIG welding.My setup - an older Clarke Turbo Weld 100EN, loaded with 0.030 wire, shielding gas 75 Ar/25 Co2 mix, regulator set at 20 L/min with 600 psi still in tank.   Power source is completely wired for 20 amp system (outlet, 12 gauge wire, 20 amp fuse at box).  If an extension cord is needed a 12 gauge 25 foot cord is used. Questions - recently I've been welding 3/16" plate (butt and right angle joints).   For the most part the welding has been decent using "C" or Crescent pattern to the weld with the usually "bacon sizzling" while welding.   On my more recent pieces, the "sizzling" noise has disappeared, a little more spat occurring,  sounds like the wire "melting" to the weld is sporadic, weld penetration sucks, and the wire material just builds up more and more instead of flowing.  Welded some flat bar as an example (attached).Checked - my tank and regulator for pressure/flow settings.  Tank pressure at 600 psi and flow was over 60 L/min, but adjusted down to 16-20 L/min with little change to weld quality.  Welder ground connection clean and retightened.   Checked wire delivery system for hangups and performance (seemed ok, but nearing end of 2 lb. spool).   Weld quality sporadic, every once and a while a decent weld comes off, but most welds are not acceptable now.  The welder and this current set has handled bigger 3/16" pieces before with no problems.  Any input/suggestions would be appreciated (even buying a new Millermatic 211). Attached Images
Reply:You may have done this already but...That mill scale on the base metal looks pretty hairy. Try grinding it clean and see if you still get the problem.Just an idea. Just a rookie in training but who knows? I get the same problems at school with plate that looks fine but won't stay consistent. When ever I take the time to sandblast the scale off the problem goes away so...E.
Reply:Check your hoses for kinks. Those dial type flow gauges read wrong if the hoses get obstructed.
Reply:also make sure your reading the gauges correctly, some of those gauges from the foreign machines are in metric and can throw you off easily....   also if your welding 2 3/16 plates together with a 100amp machine your going to need it to be wide open...  you need to bevel the materiall at the edges your weldingLast edited by brucer; 06-11-2011 at 07:13 PM.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:60 l/mn ?Try a new roll of wire.and ya might wanna check where your gauge should be set if yer gonna use the L/mn reading.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:Almost looks like the voltage is way low."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:W/ a 100 amp machine have you tried .024" wire?                                                  MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Thanks for all the replies.  Here is what I've tried so far:Clean the machine (checked all connections inside and out).  Respooled a larger 12.5 lb spool of 0.030 wire (feeds with less angle to hose).  Changed the tip and throughly cleaned the tip area (it was getting a lot of build up due to the splattering).  Still kicked out a bad weld.  Looking at the replies - I will recheck the gas diffuser, confirm/play with differnet gas flow rates, and try 0.025 wire instead.   Welding with 3/16 to 3/16" material and a 100 amp machine, I usually have the power cranked all the way up.
Reply:Your problem is that you are trying to do something that's WAY beyond the capabilities of the machine.To weld 3/16" steel, you need about 19 volts at 160-170 amps.You cant get that with the machine you're running. That machine probably gets 90 amps max with a 10% duty cycle.Get a better machine and learn the right way.Try if you will, but you'll get nowhere until you do so.Measure twice, cut once.Millermatic 211Millermatic 251Miller Dynasty 200DXESAB O/A Set-up