Interesting MIG Welding Issue

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Recently I switched over to MIG from Fluxcore to get a bit cleaner welds in corners where I cant easily brush off after welding as well as to weld thinner material with .25 wire. I am using a lincoln 180HD welder which is 240v and 90%Argon, 10% CO2 shielding gas. The problem I am having is that I am getting a heck of a lot of "stuff" on my metal after welding and I am wonderign why. With fluxcore, I could understand and in fact this stuff resembles flux from fluxcore though it can be cleared with the swipe of a finger. Attached are pics of my prep on the 1/8th stock, welder settings and resulting weld bead and "stuff" around the weld. The weld was done with push method (I prefer that because of the flatter bead) and only a slight (1/32") circular motion. Any ideas what might be going on here? Any other tips? Attached Images
Reply:Looks like 'standard' stuff when MIG welding on steel.  A quick brush (power or hand) and it all comes off.  AFAIK it is various oxides from the deoxidizers in the filler wire.  The wire brushing also gets rid of the silicon slag islands along the weld bead.  Were you really running settings E-10 with 0.025 solid ER70S-6 wire?  That seems like an awfully high setting for that wire size.And an FYI.  Put a few tack welds along the seam before you go to weld it.  You can see on your pics of the before-and-after of the sample weld how much the gap between the pieces spread apart from the original setting, all from the heat of welding.  The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by MoonRiseLooks like 'standard' stuff when MIG welding on steel.  A quick brush (power or hand) and it all comes off.  AFAIK it is various oxides from the deoxidizers in the filler wire.  The wire brushing also gets rid of the silicon slag islands along the weld bead.  Were you really running settings E-10 with 0.025 solid ER70S-6 wire?  That seems like an awfully high setting for that wire size.And an FYI.  Put a few tack welds along the seam before you go to weld it.  You can see on your pics of the before-and-after of the sample weld how much the gap between the pieces spread apart from the original setting, all from the heat of welding.
Reply:Yeah, GMAW is cleaner than FCAW, but still not as clean as GTAW.Even with GMAW there is still often a bit of clean up to do after the welding.  Just the way it is.But it is still usually cleaner than most FCAW!  And for welding on thinnner steel material, thin wire GMAW is certainly a better choice than some 0.035 FCAW-S wire.  IMHO.    The best laid schemes ... Gang oft agley ...
Reply:Originally Posted by MoonRiseYeah, GMAW is cleaner than FCAW, but still not as clean as GTAW.Even with GMAW there is still often a bit of clean up to do after the welding.  Just the way it is.But it is still usually cleaner than most FCAW!  And for welding on thinnner steel material, thin wire GMAW is certainly a better choice than some 0.035 FCAW-S wire.  IMHO.
Reply:you will still need to prep any metal if it gets painted, right just wipe or power wash.  if the stuff wipes off i don't see what the hassle is don't take this as bashing, just didn't understand. as said it's the nature of the beastidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:I weld thin metal, with fluxcore self shield regularly without problems.  I commonly use it on 16-18ga tube and sheet, plain and galvanized with .035 T-GS.  I have welded thinner as well with success, but I would guess the limit is probly about 20/22ga, with .035/.030 fluxcore.The brown dust is normal and nothing to be alarmed about.  Just brush it off and all is well.Those settings are pretty high for .023 wire.  For 1/8" and thicker, try switching to .035 wire and a gas mix with more co2, like 75/25, or 85/15.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op