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Being a rookie, I need some advice. I am welding 1/4" steel rod (at 90 degree angles overlapping). I'm making decorative pieces so I want to get a clean weld, but would rather not use a gas system (MIG or TIG). I am using a small Harbor Freight wire-feed (flux core) welder now and am getting a lot of debris around the weld (rough welds and little steel balls stuck everywhere). The steel is new, but may have some oil residue. Also, I am welding near glass and would rather not use acetylene, for heat reasons. What would be a good system, and size for me to look at to work with this material? Maybe what I've got is the answer and I just need to refine what I'm doing.Thanks for any help!
Reply:Simply the wrong tool for the job if you want nice clean welds.Gas shielded processes are the way to go.Quick mig or tig tack will do the job nice and clean.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:Not much to add to what Dave said.  I'm not sure if there are any resistance spot welders that would work for this.  Like what they use to make cattle panels.
Reply:Welcome to the forum. MinnesotaDave and Pipeliner are correct: BBs and debris from welding are just part of Flux Core welding. Part of the debris you see is flux, the protectant that shields the weld during welding. You might use an angle grinder with a cup brush to remove the flux and BBs from the weld, but in any case you will likely need some practice to produce a weld that is strong AND pleasing to the eye.Use a degreaser such as acetone to remove oily residue. If you're making these pieces, can you remove the glass to avoid overheating?Last edited by asdf; 11-25-2014 at 02:23 PM.
Reply:Also depending on how close the glass is your sparks can Pitt the glass.   Best to cover with a blanket.
Reply:Thanks all. I think I best look into MIG.
Reply:A 120v mig with .023 / .025 wire & 75/25 Argon - CO2 mix gas will be your friend.
Reply:I'm welding about 1/2" from a glass bottle. I can use a piece of sheet metal to protect it so it isn't critical. So, I'm not welding 1/4" steel plate, I am welding 1/4" steel rod. Do you think a 120V, 135/140 mig will do the job?
Reply:Originally Posted by lightuserI'm welding about 1/2" from a glass bottle. I can use a piece of sheet metal to protect it so it isn't critical. So, I'm not welding 1/4" steel plate, I am welding 1/4" steel rod. Do you think a 120V, 135/140 mig will do the job?
Reply:TIG IS the cleanest of all the processes and virtually zero spatter if done correctly.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by soutthpawTIG IS the cleanest of all the processes and virtually zero spatter if done correctly.
Reply:Originally Posted by soutthpawTIG IS the cleanest of all the processes and virtually zero spatter if done correctly.