My wire-feed welds break like solder

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I have a basic wire-feed welder. No gas or anything like that (I don't know what this would be called; I don't know too much about welding).No matter what I weld, the weld breaks as easily as it would if I was trying to use solder.I cut my exhaust pipe to unclog my catalyctic converter, and I am now trying to weld the two ends of the pipe back together. I weld half of it, and as soon as I go to flip it over to weld the other side, it breaks, as soon as I pick it up.This welder has been sitting for about a year, so the wire is probably old and rusted. I was thinking that maybe this is my problem.Any ideas/suggestions?
Reply:Are you using a self-shielded flux-cored wire, or a solid wire that requires a shielding gas (which you aren't using?)  If the wire is correct, is your polarity set at DCEN?  How clean is the steel you are welding?  What is the appearance of the wire (rusty or not)?Only "unclogging" the cat, eh?
Reply:It must be a self-shielded flux-core wire because don't even think my welder is capable of using a shielding gas.There is no polarity switch. The only control of any kind on the welder is the amperage switch (15 low, 20 high).The wire  is not rusty at all. I just looked at it and it looks almost brand new.The metal is clean. I grinded it to clean it right before I welded it.Haha well in order to unclog it, I have to rip the guts out of it. But yes, unclogging it is my primary intention Extra horsepower is just a bonus Last edited by PyroInACage; 09-24-2008 at 12:18 AM.
Reply:Let's MAKE SURE it is an FC wire.  Does it have a tubular cross-section when you cut it?  Can you bend it easily?  Is it at least .030"?  Is there any kind of number code on the spool?I had a friend with the exact same problem on an old Craftsman welder just like that.  Turns out someone had given him the wrong wire (a welding shop, too.)
Reply:I don't know what you mean by tubular cross-section, plus it's pretty small and hard to see.No it doesn't bend very easily, it's pretty sturdy. A piece less than an inch can't be bent with bare hands.It is exactly .030"The welder was given to me by my step-dad who is pretty experienced. I doubt he would put the wrong kind of wire in it.The numbers on the spool are:E70S-6Cat 42291Are either of those the numbers we're looking for?Last edited by PyroInACage; 09-24-2008 at 12:30 AM.
Reply:Originally Posted by PyroInACageI don't know what you mean by tubular cross-section, plus it's pretty small and hard to see.No it doesn't bend very easily, it's pretty sturdy. A piece less than an inch can't be bent with bare hands.It is exactly .030"The welder was given to me by my step-dad who is pretty experienced. I doubt he would put the wrong kind of wire in it.The numbers on the spool are:E70S-6Cat 42291Are either of those the numbers we're looking for?
Reply:E70S-6 is great wire, but requires shielding gas.Nothing Ever Got Done By Quitting, Never Give Up.
Reply:So my whole problem is that I haven't had shielding gas, and once I get the right wire my welds will be strong?
Reply:Originally Posted by PyroInACageSo my whole problem is that I haven't had shielding gas, and once I get the right wire my welds will be strong?
Reply:My welder doesn't have adjustable polarity.So what do I get?
Reply:Originally Posted by PyroInACageMy welder doesn't have adjustable polarity.So what do I get?
Reply:Oh awesome, I was expecting to pay at least like $50. $10 is a big relief.Thanks everyone
Reply:Originally Posted by PyroInACage...The welder was given to me by my step-dad who is pretty experienced. I doubt he would put the wrong kind of wire in it....
Reply:Or maybe he was too dumb to figure it out himself so he gave it to you to struggle! ;-)Make sure you remind him how easy it was to make some great welds with it and thank him.
Reply:its only fuxcore if the weld is bad...,, if the weld is good its fluxcore