Troubleshooting bad exhaust welds

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Doing some exhaust tubing 16 ga aluminized steel, Lincoln Handy MIG with 75/25gas. Machine is limited in the settings but its on the recommended settings (High 2, WS 9). I am stitch welding in order not to burn through but keep having the same issues:.1) On many starts I don't get an arc, just wire...then 2 seconds later it arcs and the wire sticks to the tubing.2) Some passes the welds are fine, sometimes I get what sounds like a popping noise and spatter everywhere with poor welds.3) Some passes are great, nice penetration etc, some appear cold and very lumpy...not sure where the inconsistency is coming from.My main concern is the popping, Ive replaced my ground clamp with a quality one. The workpiece is in my vice and the clamp is on the workpiece. Not sure if its a grounding issue or something else.Any help on these issues is appreciated.
Reply:Are you removing the aluminized coating in the area of the weld and under the work clamp?  Does the welder perform correctly and well on clean base metal in the flat position?  Or do you have problems welding there as well?Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:I'm going to guess ground problems through the coating also. Are you cleaning the almunized coating off?Millermatic 200Lincoln SP-100
Reply:Originally Posted by pcoplinI'm going to guess ground problems through the coating also. Are you cleaning the almunized coating off?
Reply:Do you have previous weld time with this machine or was this the first thing welded with it? Is it new or used? If it is your go to machine and just started acting up I'd try checking your whip for kinks/flat spots/burns Etc.. And make sure your wire is feeding smooth! Is the gas flowing when the wire dose not arc off? If not it may be a problem with the stinger trigger leads or maybe the leads that charge the wire at the wheel block in the welder. Just a few thoughts! Lincoln has pretty good tech support, they May have the resolution already, or have knowledge  of the same issues and a better trouble shooting procedureReal welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:Thanks for the tips, its not my first time using it. I haven't had this problem previously welding anything else. I don't know what any of those components are you talked about (whip, stinger trigger, leads at wheel block etc). As far as wire feeding smooth, I have noticed a strange noise coming from the welder recently and have wondered if its a wire feed problem. What is the proper way to set the tension on the adjuster for the wire feed? Maybe Im doing it worng.
Reply:I use a block of wood and curl the wire against it into a 2 inch circle. Just past slipping. SHould be a video on you tube. Have you tried welding some clean scrap steel?Millermatic 200Lincoln SP-100
Reply:Sorry for the terms.The whip is the chord coming from the welder to the gun (stinger)When I said wheel block I was referring to the whole assembly the tentionrer is hooked to. I also remberd I had a problem with a flux mig feeding about a year ago, it ended up being the wheels that feed the wire had a metallic build up on the little grooves that grab the wire as it goes across the wheel. it made the welder so irratic that I couldn't even get 5 seconds without it spitting and sputtering, could be some of the problem.Real welders know how to penetrate!(Equipment)Whatever can be used to beat my opponent into submission!
Reply:My older Miller also at erratic problems. The wire wasn't lined up in the groove, it was over top on the flats.Millermatic 200Lincoln SP-100
Reply:You have to sand that coating off until you see clean shiny metal and sparks when you are sanding/grinding.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Thanks guys. Going to mess with the wire feed system today and see if anything changes.
Reply:Are you cutting off the end of the wire before you start welding each time ?... What wire are you using ??When mig pops like that it means it hit something it didn't like...dirty metal ,impurity,rust,coating,etcBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:To be honest though, I've never had any problems just welding the aluminized coating before on exhaust. I'm going to guess a wire feed or tip problem....Millermatic 200Lincoln SP-100
Reply:Simply put:All arc welding processes require an electrical short circuit. A poor connection anywhere in the circuit will give you a no-arc condition.So, you have to find the (those) poor connection(s).Ground clamp, coatings, dirt, oxides, the leads from the power supply... Every single piece must do its job properly or you get a whole lot of nothing.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A