Delamninating mig flux wire?

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I've got a roll of .35 flux wire I've been using to break in my SP135. Occasionally if I am being especially klutzy  the wire sticks to the contact tip and stops feeding. When this happens I break it loose and clean the tip as necessary and all is well.Recently it started jamming repeatedly, and when I examined the wire, I was surprised to see there were two separate wires sticking out of the tip. I thought at first it had somehow managed to feed two wires at once, then realized the two wires must be two halves of the flux wire which had somehow come apart. Pulled some wire out, and it was no longer in two pieces, but still didn't look round and smooth like the wire had looked at the beginning of the roll - it was slight squared off, and had little indentations down each side.My guess is that flux wire is laminated from two pieces, and mine is delaminating. Is this a common problem? Is the fault in the machine or in the wire itself? I've never heard of this being a problem before. Oh, it's Lincoln wire.
Reply:I would say that the marks are from the knurled roller and the tension arm it to tight squeezing the wire out of shape. Check the wire on the spool it will be round.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Flux core is made from a flat foil that then is rolled around the flux, much like grandpas cigarette. Of course the indentations down the side are either the drive rolls pinching down on it or the drive rolls spinning on it when it is stuck in the tip, or both. The small flux cores are fairly easy to crush."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:When the drive rollers are too tight,they bend the wire into odd shapes and make it so that it will not fit through the round hole in the tip.So the tighter that you adjust the rollers, the worse that the wire feeds.
Reply:Sandy is close.Hobart flux cored wire(only brand I have seen first hand in production) is made by running flat material through a tube mill and,the flux is poured in when it's in a U shape and then run on through the mill.After the wire is in closed form it is then drwan to size.If you ever have a chance to see the process it is very interesting.