Cold start

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I seem to have trouble with "coldlap" on my lincoln sp-250. It only happens when I am welding 3/16" or higher. I run .030 wire 75/25. My welder has a preset for 3/16" which works really well but I cant seem to get it to weld much better at a higher setting. Do I need to step up to a bigger wire size? All I can get out of it is a lot of spatter and a weld that doesnt sound quite right to me. I forget the setting, I belive I had the machine running well around 370 IPM and 19.6 volts. Any higher than that and it seems to have a splattery sound to the weld and it always cold laps. Here is a rearend housing I did, I figured it turned out ok, I just dont have a way of rotating the housing so I had a few start stops and I didnt like the look of them. This is probly a better one. I had a good bevel and tigged the root so I am happy with how it turned out, just trying to get a smooth weld with minimal cold lap for aestethics really. The picture I showed wasnt a representation of my cold lap though sorry. Attached ImagesHTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:I could be wrong, but with those settings on .030 wire, it sounds like you could be pushing beyond the wires capabilties for short circuit transfer.  The sound is probably because it is not "shorting" anymore and is doing more of a globular transfer.  Stepping up your wire size will get you back to short circuit transfer, but not sure about the cold laps.  Someone please correct me if I'm wrong...  I'm going off of textbook info as I have not experienced this welding.Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:Originally Posted by PilotDanI could be wrong, but with those settings on .030 wire, it sounds like you could be pushing beyond the wires capabilties for short circuit transfer.  The sound is probably because it is not "shorting" anymore and is doing more of a globular transfer.  Stepping up your wire size will get you back to short circuit transfer, but not sure about the cold laps.  Someone please correct me if I'm wrong...  I'm going off of textbook info as I have not experienced this welding.
Reply:Sounds like a good plan to me!!  I love getting new equipment!   I run .030 wire through my millermatic 185, and I havn't encountered this problem yet... But I don't think I've used it to weld over 3/16" thick material.  Maybe I'll crank it up and see if I get the same results (I'm betting I will).Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:As far as which wire to get, I'm not really sure..  If you're going to spend a lot of time on thicker material, I would probably get the .045.  But I know a lot of people that use .035 as their default wire of choice..  I guess I like the .030 for the lighter gauge materials I usually work with.  If I was going to weld in the 316" range a lot, I would probably go with .035.  If I was going to weld in the 1/4" to 3/8" range most of the time, I'd probably go with .045...Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:Any recommendations for an online place to get wire and tips and such? Different brands of wire run better? I just got what praxair had what if my memory serves me correctly it was Pro Star or something like that. It ran decent I guess, dont have much to compare it too.HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:I am not sure, I dont see myself going over 1/4" but I am starting to do more axle housings and many of them have 1/4" tubes. I have been doing two passes on them but I think that could be eliminated with the right wire. Stuck between the .035 and .045HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:I really like Lincoln superarc L-56..  It works well if you have lots of millscale.  What kind of stuff do you weld on most of the time with your mig?  I get mine from Rockford Industrial Welding (LWS), I'm sure you can get it cheaper online, but I usually run out and need it right away... lol  So its worth it to me to just go and get a spool rather than wait for it to get delivered..Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:fordman, instead of waisting the 15' of wire, cut the end of the wire just past the nozzle, stretch gun out straight, hold the spool, unlatch drive mechanism and suck wire back through gun by rotating spool and winding wire back up on spool.  Just dont let go of wire while winding or you gonna have a hell of a mess.  Done this many times when changing over wire sizes or types.A few of my toys !LinuxMintManjaroMiller Roughneck 2E Lincoln WeldPak 100HTP MTS 160 Chicago Electric 80amp Inverter   Victor O/A
Reply:How often do you weld thin gauge materials with your mig?  You might want to make your choice (.035 or .045) based on the thinnest material you are planning on welding, rather than the thickest..  I know a lot of people that regularly use .035, not too sure about .045 though...Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:Ok thats what U was looking at getting. I usually make shiny steel before I weld, I try not to weld over mill scale. Ill just grab some of the L-56 probly .045HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:Originally Posted by smawgmawfordman, instead of waisting the 15' of wire, cut the end of the wire just past the nozzle, stretch gun out straight, hold the spool, unlatch drive mechanism and suck wire back through gun by rotating spool and winding wire back up on spool.  Just dont let go of wire while winding or you gonna have a hell of a mess.  Done this many times when changing over wire sizes or types.
Reply:Originally Posted by PilotDanHow often do you weld thin gauge materials with your mig?  You might want to make your choice (.035 or .045) based on the thinnest material you are planning on welding, rather than the thickest..  I know a lot of people that regularly use .035, not too sure about .045 though...
Reply:Originally Posted by fordmanDuh I am an idiot!
Reply:Originally Posted by smawgmawNo your not, I used to do the same as you for a long time until another welder showed me what I told you.  No telling how much wire I wasted.
Reply:I'll have to remember that if I end up changing wire sizes in the future too!!  Thanks!  I'd go with .045 in that situation too.  Keep us posted as to how it welds with the .045 wire.  I'd like to know just in case I need to weld some thicker material with my mig..Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:Originally Posted by fordmanI seem to have trouble with "coldlap" on my lincoln sp-250. It only happens when I am welding 3/16" or higher. I run .030 wire 75/25. My welder has a preset for 3/16" which works really well but I cant seem to get it to weld much better at a higher setting. Do I need to step up to a bigger wire size? All I can get out of it is a lot of spatter and a weld that doesnt sound quite right to me. I forget the setting, I belive I had the machine running well around 370 IPM and 19.6 volts. Any higher than that and it seems to have a splattery sound to the weld and it always cold laps. Here is a rearend housing I did, I figured it turned out ok, I just dont have a way of rotating the housing so I had a few start stops and I didnt like the look of them. This is probly a better one. I had a good bevel and tigged the root so I am happy with how it turned out, just trying to get a smooth weld with minimal cold lap for aestethics really. The picture I showed wasnt a representation of my cold lap though sorry.
Reply:Thats what I figured, but I went with the .045 mainly because I have the .030 to cover up to 3/16". I know that I rear somewhere using the smallest wire for application is better but I think this will give me more versatility.. At least I hope it does!HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:Originally Posted by fordmanThats what I figured, but I went with the .045 mainly because I have the .030 to cover up to 3/16". I know that I rear somewhere using the smallest wire for application is better but I think this will give me more versatility.. At least I hope it does!
Reply:Thats what I thought, but then I was like well .005 isnt a huge jump over what I have now.. I hope I didnt screw up but we shall see.HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:A few thousands doesn't seem like much but think of the increase in volume.Sure there is only a .010" difference between .035 and .045 thats only .005 on a side!But it makes a big difference. If I had a calculator handy I could show you. Looking at a cross section of the wire, .035 wire is like .0009 inches square and .045 is about .0015 I could be way off here, but that is a big difference. Percentage wise.I'm rambling I gotta go to bed Yup
Reply:Yea, i just calculated it out.  .030 wire is about 0.0007 sq inches, .045 is .0015.  That means that 1 .045 wire has a greater cross section than 2 .030 wires combined!  I hadn't thought of this until you brought it up Brunit, Thanks!  I'm excited to see how the .045 will work (I imagine it will be fine).  You'll probably be at a much lower WFS though.  Fordman, please keep us posted as to how it works, this is a really good opportunity to learn about wire sizes (all I have used is .030 in my mig).Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v
Reply:Originally Posted by PilotDanYea, i just calculated it out.  .030 wire is about 0.0007 sq inches, .045 is .0015.  That means that 1 .045 wire has a greater cross section than 2 .030 wires combined!  I hadn't thought of this until you brought it up Brunit, Thanks!  I'm excited to see how the .045 will work (I imagine it will be fine).  You'll probably be at a much lower WFS though.  Fordman, please keep us posted as to how it works, this is a really good opportunity to learn about wire sizes (all I have used is .030 in my mig).
Reply:Ok the .045 seems awesome and now I have an unlimited supply of power it seems like. I ran the machine at 1/4 and it welds good, I am getting some spatter, not sure why but the weld pool is really hot I can tell. I had an auxilary cooling fan come on that I have never heard before, I thought that was kind of cool. Haha and obviously yes the WFS speed is MUCH lower. I dont recall the settings but I think they were under or about 200 ipm vs what would normally be at 350 with the .03. I also dropped the machine to 14 gauge or something to tack some exhaust up and it seemed to weld that just fine. Pretty happy so far.Last edited by fordman; 09-29-2009 at 07:32 AM.HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:Thats awesome!  Glad its working well!Esab TradeMaster TorchSmith AW1A Airline TorchLincoln AC/DC 225/125Millermatic 252 w/ Spoolmatic 15aThermal Arc 190 GTSSpeedGlas 9100v