innershield 232 help

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Today i started messing around with some 232 in preperation for getting my 5 and 6g pipe certs for work.  things did not go very well, at all.here is what im working with:232 innershield .072 wireLincoln CV 400 power source with an LN-7 wire feederFillets and groove welds in both flat and vertical upmy problems:1. In the flat position it looks like a big pile of crud, no ripples, not sure if this is just how the wire runs or what?2. In the vertical ive been using a Z weave, and i can get a fairly decent looking bead, but nothing spectacular.  My big problem is blowing huge holes deep into the metal.  Then the puddle will fill in the hole and move up nicely, then another huge hole.i thought it might be my drag angle, or possibly my stickout length? ideas...Ive been welding for a few years and i have certs in 3g with 6011 7018 and short arc mig, but this is like nothing ive ever done.any input is appreciatedbtw, parameters are set at between 6 and 7 on the machine (20-23 Volts) and about 175 on the wire speed.thanks gaven
Reply:I looked at this on Lincoln's web site.  It says DC(-) polarity.  Is this the way you are running it?From Lincoln:  "High deposition rate out-of-position welding. Designed for single and multiple pass welding of 3/16" (4.8mm) and heavier mild steel, as well as some low alloy steels. Self-peeling slag. Excellent Charpy V-Notch properties." "Self-peeling slag" sounds like it should produce a nice smooth bead, particulary in the flat position.On vertical up, I'm guessing you may want to try a push angle rather than a drag angle.  Don't know cause I've heard the rule of thumb that "if its got slag, you should drag".  But, then stick electrode vertical up, you push, not drag.  Rules were made to broken anyway.Also, this is a shelf shielded wire, so you're not using gas, right?
Reply:yea im using dc -, i thought that was my problem at first too, but i have the machine set correctly.i have all that information you are quoting, and read through all of it, but couldnt find any solution to the problem.drag angle is just another term for electrode angle, which im using nearly perpendicular.  Lincoln says to use anywhere from straight perpendicular to a maximum of 20 degrees.No gas, just the wire.
Reply:It sounds like you should drop about 15 inches of wire speed and try again--this wire is VERY sensitive to parameters---stay in the puddle with steady travel speed---look for the slag shelf to follow like the cuticle on your finger to guage travel speed(you gotta have full slag coverage).Hope this helps,Jerry
Reply:welcome to the wonderful world of 232. for horizontal all you want is a slow dragging motion and it should come out fairly smooth. generally it's not going to want to peel away by itself in the horizontal position. now for the hell that is vertical you want to pulse and move in a side to side motion to start the bead that way you get a shelf of slag which will keep it from dripping out. i wouldn't do a z weave, i learned to make small circles in the upper part of the puddle that motion pushes the drops of slag forming down into the shelf allowing you to move up. and contrary to everything else if your dripping out you need to slow down. because you're not giving the slag time to flow together and support the puddle. but what would help most is some pictures so we can see what it is your doing and give you better advice
Reply:thanks for the replies guys.i had heard nothing excpet what you are saying about 232 being a royal pain in the you know what.  very sensitive to arc voltage, stickout length, and wire speed, not much room to fudge around.  I will drop the wire speed down a little and try again.Thanks for the ideas on the motion, i will try the small circles in the puddle.  I know what your talking about with the slaf shelf and keeping the puddle ahead of it.  all seems to be going well, the puddle is good sized and moving up nicely, then all of the sudden HUGE HOLE, almost like theres porosity in the base metal, similar to cast iron.Also i was told the wire has been sitting in box on the shelf since 1999.  The room is warm and dry, but im thinking that could be part of my problem?thanks againill try and take some pictures monday of what im talking about
Reply:i wouldn't think that flux core wire would be as picky about moisture as standard smaw electrodes but you never know. anyways now i'll really confuse you, i'd suggest turning up your wire speed. i generally use a 1-10 ratio of volts to wirespeed and for innershield i usually give it an extra 10 to 15 ipm. so when i ran mine i was about 22-23 volts and 215 to 225ipm but i was on thick stuff so adjust accordingly another thing is if your practicing running one bead after another the base metal is going to get real hot real fast and trying to weld on a piece of metal that's allready 500 degrees is just making things harder on yourself so cool it off or let it cool off every 5 beads or so. and i have found that a 15 to 20 degree drag angle helps to push the slag droplets into the shelf better than a pushing angle. but keep at it and don't get mad if you don't get it right away i spent a month on it  practicing 6 hours a day 5 days a week to get good at it. anyways hope it helps-Chris
Reply:thats good information, thanks iceman.  I usually keep a few peices around and rotate them so they dont get too hot.  Trying to weld really hot metal is fighting an uphill battle.Ill try the ten to one ratio with my machine, and the drag angle you mentioned.ill be back at it tomorrow morning, and take some pictures if i can find my camera.thanks again guys