Spray arc massive failure

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I can't spray arc, I suck at it, I can't figure it out, I hate it. I'm trying both c25 and straight argon, I'm getting massive porosity issues, I did increase gas flow to about 30cfh, I'm trying to weld over a 6010 root pass, and sometimes over a mig root.It's completely random when and if porosity shows up, I'm running  035 wire running about 30v and been trying everywhere from 400 to 600 ipmTrying to weld 1/2 plateAny ideas?What am I doing wrong?

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http://www.philswelding.com
Reply:Is it really the gas? I heard that people can spray arc with c25Maybe I should just give up and stick weld it all. Sent from my SM-G973U using Tapatalk

http://www.philswelding.com
Reply:Did you verify that your set up electrode positive.Lincoln 330MPXLincoln Power Mig 256Lincoln LN-25X Wire FeederMagnum PRO 250LX GT Spool GunLincoln AC/DC 225¼ Ton of Torches OFC-A OFG-AAir Carbon Arc Gouging CAC-AEverlast 62i Plasma CutterIngersoll Rand T-30 14hpInstagram: #Freebird Welds
Reply:

Originally Posted by Freebirdwelds

Did you verify that your set up electrode positive.
Reply:What’s the pink blob that looks like plastic at the end of the weld.  Might be the problem.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:

Originally Posted by Freebirdwelds

Did you verify that your set up electrode positive.
Reply:

Originally Posted by N2 Welding

What’s the pink blob that looks like plastic at the end of the weld.  Might be the problem.
Reply:

Originally Posted by Brand X

Use C-10 or a mixer on your 2 bottles. Try starting around  375/400 IPM (starting out) and lower the volts, Depending on power supply. Should start getting into spray at 26 volt, and just get a few crackles on the lower end of spray.. Recess your tip into the nozzle. Always push the gun if possible, and hold a decent standoff too This should get you there, and move up voltage, and WFS as needed
Reply:

Originally Posted by MetalMan23

Still glowing red when I took the picture Sent from my SM-G973U using Tapatalk
Reply:Yes,C-25 takes too many volts to get into spray with C-25.. Get some 98/2 (Lowest volt spray) or some 90/10 Argon/C02Esab/Lorch ET-220iEsab 160i caddyEsab CV353Thermal LM-200/ Lincoln feedersThermal 60i- 3phase Pak 50Thermal 35CThermal 15cINE 1500 Klutch 220iBlue Demon/140 msi/90sti
Reply:Some people will argue the point but the generally accepted wisdom is you need more than 80% argon to spray. I use 90/10 with no issues.
Reply:And I guess 100% argon won't work? I don't want to have to get another whole tank just for this job, Sent from my SM-G973U using Tapatalk

http://www.philswelding.com
Reply:100% argon will work for Aluminum.. Pick up some .045/,052 Dual-shield wire and run it with 75/25 gasEsab/Lorch ET-220iEsab 160i caddyEsab CV353Thermal LM-200/ Lincoln feedersThermal 60i- 3phase Pak 50Thermal 35CThermal 15cINE 1500 Klutch 220iBlue Demon/140 msi/90sti
Reply:

Originally Posted by Brand X

100% argon will work for Aluminum.. Pick up some .045/,052 Dual-shield wire and run it with 75/25 gas
Reply:Mix the Argon and the C25 to get a 92/8 mix.  You can use something as simple as a T or Y.

Here is a chart I made to generate 92/8 mix.



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Reply:

Originally Posted by MetalMan23

Maybe I should just give up and stick weld it all. Sent from my SM-G973U using Tapatalk
Reply:

Originally Posted by MetalMan23

And I guess 100% argon won't work? I don't want to have to get another whole tank just for this job, Sent from my SM-G973U using Tapatalk
Reply:Perhaps slag pocket from the 6010 percolating through, since you say it is random.  Also, could your wire be rusting?  I doubt it is gas if it works then does not work???
Reply:Wrong Gas Mix. Google a bit before you waste all your gas.Thermal Arc 320SP ( Lorch )Cobra PythonsThermal Arc 300 AC/DC  ( Sanrex )ESAB 301i AC/DC  ( Lorch )Thermal Arc 161STL  ( WTL )Thermal Arc 190S  ( Sanrex )Cut Master 82, 42. Cut45 ( WTL )Victor Gas Apps.Boxes and boxes of welding crap.
Reply:Phil, first off if you are determined to spray arc it, do yourself a favor and step up to 045 wire, and the correct gas. 045 wire will run better on that thickness of plate. Second, how critical are these welds? Dual shield will work but I am wondering if you can get by with something like a Fabshield 21B self shielded flux core. You could run the 045 or 1/16th wire, forget the gas and lay down 3 lbs of wire an hour at about 200 amps. It should be plenty strong enough.Miller Multimatic 255
Reply:

Originally Posted by Louie1961

Phil, first off if you are determined to spray arc it, do yourself a favor and step up to 045 wire, and the correct gas. 045 wire will run better on that thickness of plate. Second, how critical are these welds? Dual shield will work but I am wondering if you can get by with something like a Fabshield 21B self shielded flux core. You could run the 045 or 1/16th wire, forget the gas and lay down 3 lbs of wire an hour at about 200 amps. It should be plenty strong enough.
Reply:I's use Dual shield with your C-25 gas or straight CO2. Fabshield 21B isn't nearly as strong or have as much penetration and has a lot more smoke. If you had lots to do and it's in the flat position get some self-shielded E70-T4. It has the highest deposition rates. I used some 3/32" at around 400 amps and went through a 50lb. coil in 2 1/2 hours. Just make sure you have a good ground so you don't get arc blow. Weld looks almost like sub -arc.https://www.lincolnelectric.com/asse...3M/c320002.pdf
Reply:not sure how powerful your machine is but mine sprays fine with 85/15 and can still short circuit on the same bottle. metal core is good for putting down alot of material.i see your working outside. likely the wind may be blowing away your gas. use self shield fluxcore or wait until the wind is very lowinvertig 221 water cooledhypertherm powermax 30xpfronius transpocket 180fronius transsteel 2200fronius iwave 230i water cooled
Reply:Dual shield in 1/16 is fast and clean, flux core in 5/64 like Lincoln NR 311 or even 233 world make short work of that. Make sure you not having problems from going over the 6010 like not floating out contaminated from the root pass. It looks like too much voltage add wire speed or subtract voltage to get right at the transition point between spray ang globular transfer and dial in from there looking to work in the lower range of the voltage/wire-feed-speed at first. Mixing the gas could work out but trying to change too many things at once can be confusing. You know how the roots went in so if they were clean 7018 does a great job running over 6010 roots but mig wire might not be as forgiving.
Reply:I think it's nothing to do with the gas, and everything to do with the 6010 root pass. MIG doesn't allow the impurities and hydrogen to escape easily. MIG likes clean, high quality metal. Even a bit of trapped slag would do what you see there.Murphy's Golden Rule: Whoever has the gold, makes the rules.