1/16th flux cored..HELPPPPPPP please..asap!

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ok...so today at my shop, I was welding flux cored .45 on a giant pipe spool just a normal day, and so it went down hill when they said we have to switch to 1/16th welding wre because our customer prefers it now out of the blue. so they brought in this huge shipment of 1/16th. I was worried but, my Q.c. told me its the same process as .45 which i'm good at. by the way my every day wire speed is around 450 or 4 1/2 and my heat is around 27.5. so I set the 1/16th to my normal .45 settings...I cleaned my weld which was going to be about a foot of a pass which is normal for me. so I cleaning my area grinded the rust, wire wheeled the dirt and sprayed on some anti splatter....also I haven't gotten major porosity in over a year fyi..so I struck the arc and holy ****....sparks went every were it sounded like it was to cold but the ****ing puddle built up so quickly. at my shop restarts are not allowed after your 2nd month so I didn't stop. since it was a long bead I welded one handed back and forth motion (back and forth it easier for me when I weld one handed andnever had I experienced under cut or poro. I finished the bead without a physical problem..the slag shell made it look like a clean weld so I got excited..I knocked off the shell AND BAM porosity so bad not even chicken scratch but full blown holes...wtf..Please help me with this because after the Poro I did test welds on scrap and the same thing..? Remember the first time is so long that I've gotten poro. any ways, I checked everything I had a Clean nozzle before the weld and a clean 1/16th tip...please help me conquer the beast of 1/16th flux cored..Any heat suggestions wire speed? any thing I need to do different than I do for my .45? I'm confused because the QC said treat it as .45....Please help..I did detail in this post because that's exactly what happen with my use of 1/16th I don't know any other way of explaining it..PLEASE>>
Reply:Look at the manufacturer's spec for wire stick out. Some are any where from 3/4-inch to 1 1/2-inch. Generally they are not kidding either! Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:well..the machines I am using are old school millers so you hae to hear the puddle build up during welding to adjust everything.. -.- what about welding techniques like motion wise..I need all the help I can get with this please..
Reply:It's all the same. I think you have a mental block, moving from .045" to 1/16-inch wire. It's like welding all the time with 3/32-inch 7018, then have to use 5/32" or 3/16-inch 7018. It's still the same thing, you just have to carry more iron! Go back to basics. Wire speed / amps, volts, stickout, cfh of gas.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:yea..just sounds so different from normal .45....and I used the same setting and completely butchered my weld idk I'm stuck because UT is coming up...
Reply:I don't know how to fix it via the Internet. If I was there, I've yet to see a machine I can't dial in.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by CEPI don't know how to fix it via the Internet. If I was there, I've yet to see a machine I can't dial in.
Reply:Originally Posted by watch-me-weldyea..just sounds so different from normal .045....and I used the same setting and completely butchered my weld
Reply:Originally Posted by BurpeeYou've never experienced the crappiest flux core wire that should be stolen and never bought.
Reply:ok, It's just discouraging to see all of those holes, it made weld look like crap..the only reason I had the setting the way they were is because I was told to. Is 1/16th needed to be ran cooler??I don't know what it's supposed to sound like when it's ran correctly...idk what to do..
Reply:I don't run 1/16" FC, but my guess is it should sound just like the .045 does when your settings are right. No way I'd assume the machine needs to be turned down. 1/16" is bigger wire than .045 and almost every wire I've run when you go up in size, you go up in settings for the most part.You keep typing .45 FC, but I assume you mean .045 FC wire, not wire that is close to 1/2" in size. If you are pushing 1/2" wire, I want to see the toys you get to weld with!You don't list the actual wire you are using, so we can't even look up the specs for you for suggestions..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:What did the manufacturer specs say when you checked?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:dude way WAY WAY to much wire speed. you ran .045 at 450 now you have an electrode thats twice the size. Turn the wire feed down, increase your stick out.
Reply:Post some pictures of you can.  We run 1/16 Dual shield.  More specifically ESAB 710X.  I know if we use anti spatter and if it doesn't have time to evaporate it causes what we like to call gopher holes and worm tracks as that is the best way to describe what the weld looks like.  We also get that from our nozzles getting bad.  The nozzles we use have a built in fiberglass type insulator and when they go bad the weld goes bad.  seabee78
Reply:I really like ESAB's 710X, childs play to run.  Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:^ could be better. Weave looks slightly cold. Just saying. Op ive ran tons of .045, 1/16, and 3/32. Try around 25v and 269wfs. --Gol'
Reply:Originally Posted by Go1lum^ could be better. Weave looks slightly cold. Just saying. Op ive ran tons of .045, 1/16, and 3/32. Try around 25v and 269wfs.
Reply:So great news, actually. I was able to handle my 1/16th problem with 29 heat and 24 speed  went great passed all my UTs..my problem was had my settings jacked up beyond belief...thanks fellas...still trying to understand why 1/16th though..Oh and the brand is select arc 1/16th 737
Reply:your double caps look to cold..
Reply:Sorry man, i just seen your pm....something up with the notifications and the link between my phone and tapatalk...Glad to hear you got it figured out. seabee78