Nozzle Size for .025/.030 Wire?

admin

I'm converting my little Weld Pak 155 from .035 flux-core wire to .025 OR .030 standard wire w/gas shielding (C25) and there are three different-size nozzles from which to choose = 3/8, 1/2 and 5/8. 95% of what I'll be welding will be 1/8" or less mild steel, sooooo.........I'll PROBABLY get a 10/11-lb spool of .025 (.023?) Lincoln wire, but I'm not sure which of the three nozzles to get. Also, the contact tips that are available for the smaller wire are .023 and .030. If the Lincoln wire is only available in .025 diameter (I haven't checked), should I get the .030 contact tip? Sorry for my newbie ignorance!! TIA. 2015 AHP 200X TIG (Just received "re-ordered" unit on 8/26 after UPS  lost the first one)Lincoln 155 Weld Pak MIG(Old) Marquette O/A Set(Old) Miller 225 "Thunderbolt" Stick (for sale)
Reply:Hello TurboRay, larger is generally better (for coverage purposes), and if you go smaller, base your size choice on access issues. Also consider that when you change the nozzle size you "technically" should change your gas flow rate too (less flow for the smaller nozzles and more flow for the larger ones). Main reason being that the velocity of the gas exiting a nozzle will increase with a smaller nozzle set to the same rate of flow for the larger one and possibly cause turbulence in the gas coverage and cause a draw of atmosphere to contaminate your shielding. So adjust shielding gas settings on nozzle diameter. Good luck and best regards, Allanaevald
Reply:Half inch is the normal for the smaller migs. Unless you're going to do a whole heck of a lot of work in tight spots, then you might think about a 3/8ths. To be technically and politically correct, if you move down to the 3/8ths nozzle then you should transition to the tapered tips too or you could find yourself sealing off the gas flow with the tiniest bit of spatter. With a drill and grinder you can taper your own tips I suppose."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:The contact tip should match the wire diameter, not one size larger.  0.030" is a good all-around wire but you would need to experiment with your machine first to see if it will properly handle the range of metal thicknesses you anticipate. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Did you buy the mig conversion kit, or did it already come to you with it?(In other words, does it have a gas hookup in the back of the machine?)Attachment 1179781Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:No, Dave - I bought my Weld Pak 155 new as a flux-core wire welder. I'm converting it to MIG by using the directions in the following You Tube video: I ordered the 220V gas solenoid on eBay for 24 bucks w/free shipping (LINK) and I'm gonna get the contact tip & nozzle from USAWeld for about $11 + S&H. I already have a Harris flow meter that I bought a long time ago in anticipation of this conversion. I'll probably get the miscellaneous hoses and fittings at my local hardware store or Home Depot. Last edited by TurboRay; 08-07-2015 at 02:33 AM.2015 AHP 200X TIG (Just received "re-ordered" unit on 8/26 after UPS  lost the first one)Lincoln 155 Weld Pak MIG(Old) Marquette O/A Set(Old) Miller 225 "Thunderbolt" Stick (for sale)
Reply:Sounds like a good plan to me - you'll like gas shielding Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:.023 tips will work just fine for Lincolns .025 wire. I have never understood why Lincoln makes their .025 when almost everyone else draws it .023......maybe so people think they HAVE to buy Lincolns tips?
Reply:.023, .024, .025", 0.6mm are all the same thing. Different manufacturers designate it differently for reasons lost to history. Tips are several thousandths larger than actual wire diameter so no worries.JohnA few weldersA lot of hammersA whole lot of C-clamps