hot balls are killing me!!

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Ha Ha,...I'm doing a job welding 3/16" 1018 plate with thru hole to 1\2" 1018 shaft, a button weld. I' using mig with s6 .30 wire, 75/25 gas and anti-spatter spray. I made a jig that holds 25 weldments. I tried everything I know and cannot reduce or prevent weldments from being covered with massive amounts of hot balls. Here are a few pics. Can any of ya'll Gurus help?? Attached ImagesMiller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:I use Pam cooking spray sometimes. That or anti-spatter. Another possibility would be making tin foil shields; the foil will die, but the time it would buy you will keep the balls off the project long enough to cool them so they will not stick.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:What are your settings?  I am guessing you are running too small of wire.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Ever hear of three modes of metal transfer in MIG welding?  Short Arc, Globular, and Spray.See this video and read the Miller, Lincoln, and ESAB MIG welding guides online.http://weldingweb.com/vbb/showthread.php?t=13218
Reply:Pulser-Thats a nice video!!!!!Thanks for the link!
Reply:It is difficult to go into a spray with 75/25.  I suggest at the least 80/20 or a mix intended for spray transfer. ( high argon)  The other alternative is to turn your machine down until your voltage is around 20 and use short circuit transfer.  The job would take at least twice as long to weld but cleanup would be minimal.
Reply:Hey guys, HELP!!,   This job is killing me. I have tried tig welding, stick welding, and mig welding. I cannot achieve a consistent weld. I think over heating is the problem. In the time it takes to transfer enough filler to weldment, it is way hot. I bid this job expecting to make welds in one pass. Any suggestions?                                                  Thanks, Wes Attached ImagesLast edited by wagin; 10-31-2008 at 11:18 PM.Reason: picsMiller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:What happened to the Posts????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:Originally Posted by lotechmanIt is difficult to go into a spray with 75/25.  I suggest at the least 80/20 or a mix intended for spray transfer. ( high argon)  The other alternative is to turn your machine down until your voltage is around 20 and use short circuit transfer.  The job would take at least twice as long to weld but cleanup would be minimal.
Reply:Why are you filling the entire hole?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:This is a job for .045 wire rather than small stuff.. In fact if you can run it .052 would be better.  You need to go into spray to get rid of the spatter and you need around 350 inches per minute on .045 to make any time .  Gun vertical and a circle around then into the center to finish off.  I am hoping you have a power source with adequate amperage.  If not you are going to be doing this job for a long time.
Reply:Looks like it could be tough to get any root penetration with those not being flush, at least from the picture.  I've melted some really thick stuff with my sycro 250..I know that doesnt help.  Is there a problem with getting the fixture too hot and causing distortion? weld it like you own it
Reply:I'm filling the entire hole due to the shaft being 1/16 recessed. The job calls for a button weld with 1\8 penetration, 3/32 max weld height, and 3/4 max weld diameter. As far as mig goes, I'm using a Lincoln power mig 180 with 0.30 wire and 75% argon-25% co. I just returned from shop, I maxed out amps and wire, applied generous amount of spat spray and it worked somewhat decent. Attached ImagesMiller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Originally Posted by Broccoli1What happened to the Posts????
Reply:Originally Posted by waginI'm filling the entire hole due to the shaft being 1/16 recessed. The job calls for a button weld with 18 penetration, 3/32 max weld height, and 3/4 max weld diameter. As far as mig goes, I'm using a Lincoln power mig 180 with 0.30 wire and 75% argon-25% co. I just returned from shop, I maxed out amps and wire, applied generous amount of spat spray and it worked somewhat decent.
Reply:Originally Posted by lewray sounds like a good job you got
Reply:Originally Posted by waginCan you be more specific?
Reply:Yes I agreetime to buy a bigger machine and a gas intended for spray to reduce spatter.  You have thought out the fixturing obviously so you are no dummy.  Crunch some numbers and look at how long to recover the cost of a new machine.
Reply:Originally Posted by Broccoli1Posts in the Thread that have vanishedI swore we wuz joking about Hot Balls and Cups.Anyhoo- Looks like it is time for a bigger machine, eh?
Reply:Originally Posted by David RNo posts have been deleted.  There is another thread similar to this one.I hope the original poster can do a few for a dry runs to make sure his price is good.David