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I've been having intermittent porosity issues and in the last week they have gotten horrible. I'm running a Millermatic 175 that I have had for several years now with no issues. Today I swapped out the gas and wire. The stinger is less than a year old, new tip, cup, etc. Still have major issues. Tonight I swapped the regulator out with a friends Miller 211. Tried his gas tank. Nothing worked. I then tried his welder...and no issues.So my question is what could be wrong with my welder that would be causing these problems? I'm getting gas flow, no issues there. I recently switched to a magnetic ground clamp, but I put my old clamp on tonight and same problem.All the steel is brand new and clean.I'm at a loss and ready to just go buy a new welder.Thoughts? I'm going nuts and in the middle of a big project. And this is a major issue as all of my furniture I make is bare steel with ground welds 75% of the time. No way to fill and hide the issues.Thanks.
Reply:Porosity comes from 2 things, dirty material or poor/no gas.The fact you can get decent welds with the same gas and same material with someone else's machine, tends to make me think it's a gas flow issue with your machine, and not a material or bad gas issue.With the wire feed wheels disengaged, you should be able to hear and feel gas coming out the end of the gun. If you can't, or it's just dribbling out weakly, you have something blocked or misaligned.1st thing I'd probably check is that the gun hasn't gotten pulled out slightly and partially blocked the gas port. I'd take the gun out completely and reseat it making sure it goes all the way in. I've seen this happen when someone needs just a tiny bit more "hose" and tugs on the machine, or drags the cart around by the mig gun as they work.2nd thing I'd look at is the other end of the torch and make sure the gas ports on that end aren't blocked. It's been a while since I used my small M10 gun on my Miller, but the students at the tech school are constantly pulling the nozzles off the Tweeco guns and partially unscrewing the insulators blocking the gas ports. A heavily fouled nozzle will also cause issues on occasion..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:Thanks for the feedback. I checked the seating of the gun in the machine last night, it's in right and tight.Gas is flowing, I even checked it at different flow rates and you can feel it coming out and feel the difference. I usually run about 30 CFH, experimented with less and more with the same results. I was having this problem last year when I realized my gun was coming apart inside, it's an older welder that I bought used from a friend. Problem went away when I replaced the gun. Calling the welding supply store today to get their input.Jobe Fabrications
Reply:Have you tried running the two different machines in tha same location? I wonder if your having an atmosphere interference with the gas.
Reply:Ran them both on my bench last night. It's not the shop.Jobe Fabrications
Reply:Find out what is 'different' and go from there.You say the machine was working fine, then you swapped out the gas cylinder and the wire spool and then had the porosity problem?That leads me to suspect first the gas or the wire spool or something related to those items.Did you accidently nick or ding the regulator seat when you changed the gas cylinder? It doesn't take much to mess things up sometimes. When you changed the cylinder out, did you accidentally pull or tug on the gas hose leading from the regulator to the machine? Did you bump or tug on the gas fitting on the back of the machine?Get some soapy water and check every accessible gas connection or fitting for a leak. Check the entire hose running from the regulator to the back of the machine and check (double check) the seating of the torch hose into the front of the machine. Check the o-rings where the torch hose goes into the front of the machine.If you swapped out the gas cylinder for another one that worked fine on another machine and neither gas cylinder gives you good welds on the one machine, then the issue is not the gas in the cylinders. If you took 'your' possibly-suspect cylinder that is giving you porosity on your machine and put it on another machine and you get 'good' welds, then the issue is not the gas in that cylinder.Check things out methodically, one item at a time. Start with the 'easy' stuff. You have (or have access to) another machine? Swap things out, one at a time, between the two machines and see what (if anything) causes the porosity problem to jump between machines.Swap gas cylinders. No change in the behaviour between the two machines? The problem is not the gas or the gas cylinder.Swap wire spools (you said you just put a new spool on. With name-brand wire, unless you have a rusty spool of wet wire, wire doesn't really go bad. Off-brand wire, you might have some crappy wire on the 'new' spool). Swap out the wire spool for a known 'good' spool.Swap out regulators (and the low-pressure hose that runs from the regulator/flow meter to the back of the machine) between the two machines.Follow the gas-flow path and check or swap out things, one at a time. Cylinder to regulator/flow-meter to low-pressure hose to machine to torch hose. The best laid schemes ... Gang oft agley ...
Reply:I was having the issues before the wire and tank swap. Last night I spent 2 hours swapping things out one at a time...luckily my shopmate has a nice Miller 211. First swapped the tank. No change. Then I swapped the regulator on his tank and then on mine...no change. Then I just used his machine and no porosity issues...so rules out the steel. Just got off the phone with my welding supply I use and I'm taking the machine in this afternoon for them to look at. As backup they have a brand new 211 in stock ;-)Jobe Fabrications
Reply:Did you swap out the MM211s gun and run it on your MM175? Ive damaged one of the two O-rings on the welder end of the gun and had issues, are they both okay? If the MM211s gun on your machine still has porosity in the weld you may have a pin hole in the gas line between the solenoid and the drive assembly. Let us know what you find. Good Luck!Everlast PowerPro 256, Everlast W300 Cooler, Everlast Cart 250Millermatic 211, Spoolgun 100, Miller HD CartJackson W60 Truesight Digital Auto Darkening, Victor 315 Torch sitting on a Harper 830-86 cart
Reply:Took my welder in for service, explained what was going on and they were stumped as well.Got a call 2 hours later saying it was my nozzle! The stop inside the nozzle had broken loose and was letting air in the backside of the nozzle. Crazy! New nozzle and a clean bill of health on the diagnostics machine and we're back in business. They had never seen that problem before either.Jobe Fabrications |
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发表于 2021-8-31 22:52:46