Question about mig welding - end of wire balls up

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When I mig weld on gas(can't say it happens on flux) I would be welding and sometimes the end of my wire will look like it's balling up and drip off. While it's balling up, the crackling stops and I just hear what sounds like the burning of the gas.  What's going on?
Reply:What settings do you have your machine set at?  How thick of material?  What size wire?  What gas mix are you running.  If you're running a small wire and high voltage / wire feed speed, you could be starting to get a globular transfer instead of a short circuit transfer...  More information would be helpful though..Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:It's a 110 welder, .30 wire, the metal, I'm not sure, but it's pretty thick for what the machine says it can handle.  Using a 75/25 mix.  I think since I've cleaned my gun(wire and gas) it's gotten better though.  Just didn't think there was numerous times when the wire could glob up like that.
Reply:Originally Posted by grphxIt's a 110 welder, .30 wire, the metal, I'm not sure, but it's pretty thick for what the machine says it can handle.  Using a 75/25 mix.  I think since I've cleaned my gun(wire and gas) it's gotten better though.  Just didn't think there was numerous times when the wire could glob up like that.
Reply:I'd bet money there's a wire feed problem.  Sticky tip, liner, or wrong tension settings.My name's not Jim....
Reply:Yep, I bet wire feed is slowing down. I have that happen when I get the gun bent around in a weird position, wire barely feeds and you hear a hissing sound. Also happened when I got a piece or crud in the liner and it would bind the wire up.HH 187Miller Bluestar1EAHP AlphaTig 200X
Reply:If you switched from flux core, did you change polarity too?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:The wire feed speed might not be turned up high enough. with the wfs turned down on my PM140 it can make an ok weld with the gun farther away from the work, but when you get closer and the amps increase, the wire just cant keep up and it drips as stated.Miller Dynasty 300dxSpeedglas 9002XMiller Spectrum 375 XtremeLincoln PowerMig 255xtLincoln PowerMig 140cMilwuakee Portaband
Reply:Hows your "burnback" settings?Might want to consider changing this abit to see if it improves your problem, it is usaully in the wire storage box of the welder, also your tip, as the wire loops through the gun it contacts the tip on exit and the fit isn't very tight as you think it would be, change it, they are not expensive, I try to keep a small plastic box of consummables/tips handy; balling is usaully an indication of damaged or worn liner, if it persists its the liner.This can happen by pulling the wire back from the wrong end or long term wear and tear.
Reply:I'm sorry, I forgot to tell you what the burnback setting controls, it allows you to adjust the amount the wire melts back from the front of the wire where it makes contact with the metal you are welding to your contact tip of your gun controlling melted metal globule size and is usaully in the form of a potentionmeter control in the wire basket area.This is always a factory set value, initially.
Reply:Originally Posted by BoostinjdmI'd bet money there's a wire feed problem.  Sticky tip, liner, or wrong tension settings.
Reply:Howdy in addition to all the great suggestions posted some of the things that have given me fits is the liner becomes dirty, wire coming off the spool (esp the small) has a memory to it sort of like fishing line coming off an open face reel. When your liner is dirty and you don't have enough tension on your rollers and you have sharp bend or you may have even accidently tugged on the whip and put a kink in the liner you will have erratic wire speed and blobs will happen. I would go to square one clean your rollers put in new liner and tip etc. That's not to say the input of settings and technique are not a factor. Hope this helps.
Reply:Their is also a wire cleaner you can buy for mig welders, I've seem them listed for $30.00 and they are guite simply a large office paper clamp with some green 3m scotch bite folded up placed before the wire inlead.
Reply:Feed problem, also verify polarity (solid wire/gun +)
Reply:Looks like all the possibilities have been covered.  If you find it to be something other than what is listed, let us know.
Reply:If you switched from flux core to solid wire did you also change the feed rollers?G3miller... 225g, s32p, 250x, 304, 12vs, MSW41     victor o/a thermal dynamics cutmaster 50 lenco panel spotter        hobart hf-boxG3 Farms.....raising cattle, hay, kids and hell, ...oh yeah I'm a fire sprinkler contractor by trade.
Reply:Not neccesary, but, would advise to:Knurled Rollers - Flux CoredSmooth - SolidAluminum - Dedicated Drive Rolls & Gun Liner (teflon)