Help - flexcore welds inside tip

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While welding with flexcore .035, with an SP135 + Lincoln, Wire setting 3, volts E. Wire gets welded inside the tip (not a burn back). I can give the wire a jerk and pull it loose, but it just happens again. By the time I got a new tip it was getting to dark an we quit.A day earlier, it was happening with .030 flexcore, after it happened 3 times in a row with replacing tips each time. What I did to stop it was to change to 035 tip, with .030 wire. The problem went away. Now It's happening to 035 flexcore and .035 tips. I do have .045 tips.Vern
Reply:Sounds like you have the voltage set too high for the wire speed.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Also watch your stickout when you start the arc, or while welding.  Bury the tip in the puddle and it can cause problems like you're having.  Leave around 1/2" stickout when you start the arc, and watch the wire as you're welding.Sometimes shorting the tip against the steel will cause problems too.  I run flux core without the gas nozzle so I can see better, and I have to be careful not to accidentally touch the fitup clamps when tacking"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Another point, the wire and tip should mach. If the tip is larger than the wire, you’ll get arcing inside the tip that will weld the wire to the tip.
Reply:Make sure your ground is real good. Mig needs a very good ground.
Reply:If you have checked items mentioned then would be a feed problem. Change your liner and check tension on wire, gun connection etc.There should be no need to use an oversize tip all things being equal. Check your wire by running through fingers lightly to see if you can feel any little "bumps" .
Reply:Great replies! I won't find out whats gotng on until it gets light, 5am now.After I clean things up, after the fire. http://www.enichesoftware.com. See Projects/Fence video-5, 6. Welding in dead grass.DesertRider331) I think my volts are to high. Using wire 3 - volts Efarmersamm2) Stick out. I have been burning the wire off instead of cutting it.Bob3) Thanks transit I'll stop using larger tips and look for other causes.Billy4) I'll make sure my thumb screws are tight. Been changing a lot of wire.All great replies. THANKS!I thank today will go much smoother.Last edited by Vern2; 12-19-2009 at 07:39 AM.
Reply:Originally Posted by Vern2Great replies! I won't find out whats gotng on until it gets light, 5am now.After I clean things up, after the fire. http://www.enichesoftware.com. See Projects/Fence video-5, 6. Welding in dead grass.DesertRider331) I think my volts are to high. Using wire 3 - volts Efarmersamm2) Stick out. I have been burning the wire off instead of cutting it.Bob3) Thanks transit I'll stop using larger tips and look for other causes.Billy4) I'll make sure my thumb screws are tight. Been changing a lot of wire.All great replies. THANKS!I thank today will go much smoother.
Reply:Transit,On Going project..".128 galvanized posts to .065 rails"from an earlier Thread Vern posted.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Wouldn’t 0.030 be more suitable with a faster wire speed?
Reply:Machine not withstanding, .030 or .035 fluxcore are both acceptable wire choices for the items being welded.  With his 110v machine, .030 wire would be the better choice than .035 for the items being welded.My Passport burns .035 fluxcore very well on 110v power, but the Passport also has alot more output on 110v than his SP135.   Passport @ 110v = 150 amps max output.Last edited by DesertRider33; 12-19-2009 at 12:45 PM.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Yes, i was thinking along the very same lines. He still needs to solve the burn back problem.