First time using flux-core, what a mess...advice?

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so i've been borrowing a good buddies MM135 for a while now...until i get my own (looking at MM211 or HH210) or he wants it back. i've been doing projects, and practice with different metal scraps/thicknesses/angles/etc. as much as i can. c25 gas is hooked up, originally was using .030 solid wire, when that ran out, my friend recommended .023 as he felt he had better control and better welds with it. so i took his advice and got that. not sure if it was the wire or the practice or both, but my welds were looking better and better and i was really becoming happy with my progress and look/strength of my welds....then the gas ran out. i dropped his tank off to get refilled (he owns a fancy aluminum tank), the holiday last week screwed up timing so it was gonna need to be about a week or more to get it back (needs to be sent to fill center and sent back). i figured i'd play with flux-core in the mean time. i know it has a bit better penetration and takes the little 110v machines up to their peak/max performance.i DID reverse polarity appropriately, hooked up the correct tip and the spool of .035 wire. damn, what a mess! splatter everywhere, slag to clean, etc... i've been hitting with the wire wheel to clean after and see how they are looking. they are ok, and they were getting better, but nothing near as pretty as with the .023 and c25.is there a way to get pretty welds with flux-core, or is the process just ugly, even if the weld is good? any tips to get better looking welds with flux? should i have gotten the .030 instead?thanks guys
Reply:The flux in the core of the wire takes the place of the shielding gas- sorry if you knew that already- so the slag will be a given, and you should expect cleanup. The wire wheel will help a lot with that. FCAW splatter and BBs is the nature of the beast, unfortunately. You can get acceptably good looking welds, but I doubt if they will ever be featured in the "MIG Like TIG" post on this forum.
Reply:agreed, flux core is just not a pretty welding optionDynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:Originally Posted by turkagreed, flux core is just not a pretty welding option
Reply:You just need more time with it- Fluxcore can produce purdy looking welds also.Not sure if you know.. but you should be dragging- you don't want to Push when using Fluxcore.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:There was a post by a new guy in the past month or so that had a flux welder from harbor freight. It was some of the best flux wire welds I've seen!Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:When asking about things like this it helps if you tell us what your settings are What the wire is E-?... who made it ..Stick out lengthPics if you have them helpA lot of wire needs to be cut off for restartBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:FWIW.... It's "spatter," not "splatter."   Make sure you have the proper terminology or else the welding nazis might  come down on you.Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:Oh BoyBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:At my job all the structural part is welded by flux-core and when im walking into the shop on my lunch break and look at those welds i have to say they look great, some of them look as the same ''curly'' equal beads as solid MIG wire, only the finnish of the metal is not the same, look always dirty! But like someone said, when it goes with flux core i think that its always about the property and the strong of the weld way more than the look!Calculator > Bevel Square
Reply:I can't find the one I'm looking for but this is the next best one I found.http://weldingweb.com/vbb/showthread.php...ht+flux+welderTorchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by Broccoli1You just need more time with it- Fluxcore can produce purdy looking welds also.Not sure if you know.. but you should be dragging- you don't want to Push when using Fluxcore.
Reply:One thing about flux core is your wire speed will be a lot slower than with solid wire. I use it on my small machines, Lincoln 135 and a 180, and the highest setting I use is about 50% of the dial and thats with the voltage maxed out. It takes a little getting used to but you can make some nice looking welds with it. I use nr-211 ut I prefer hobart fabshield it just costs more.Millermatic 250Lincoln 180TLincoln SP-135Miller Thunderbolt AC/DCThermal Arc 161SAirco 300 Heliwelder
Reply:Originally Posted by Wstmrlnd89639One thing about flux core is your wire speed will be a lot slower than with solid wire. I use it on my small machines, Lincoln 135 and a 180, and the highest setting I use is about 50% of the dial and thats with the voltage maxed out. It takes a little getting used to but you can make some nice looking welds with it. I use nr-211 ut I prefer hobart fabshield it just costs more.
Reply:Don't give up on the flux core self shielding wire.  It does work well if you get used to it.      These are welds made over quite a few years.  The very last pic is one made with a top of the line machine (LN-25 powered by Ranger GXT).  They're all acceptable welds, even when made with a smaller 110v machine, as in the first four pics.You'll find that reduced stickout, rather than the reccomended stickout, will give you the best results.  I find that long stickout makes for very ugly welds.  The higher amps when using a shorter stickout really wets the puddle in.  Self shielding flux core, in my experience, tends to burn back too much with a recommended stickout.For a 110v machine I favor .030 wire.  For a bigger machine .035 works very well.  I never really liked .045 wire for some reason.  The larger .045 wire doesn't gain you any real thickness advantage, all self shielded wire is limited to 5/16 material in these sizes."Any day above ground is a good day"http://www.farmersamm.com/
Reply:I generally run fc hot. My slag looks kind of tan or brownish and flakes off. I dont mess with. 035 just. 045-.072Sent from my DROID RAZR using Tapatalk 2
Reply:nice welds farmersamm, thanks for the tips too. what is the 'Uranus Inc' all about?
Reply:Originally Posted by wicked4x4nice welds farmersamm, thanks for the tips too. what is the 'Uranus Inc' all about?
Reply:For the SPATTER problem with flux-core I use 'PAM' or any off brand equivalent. It really stops the spatter from sticking and it smells good too! HF 151 Dual Mig Welder (with mods)Lincoln 225-S AC WelderBuffalo MM-1 Milling MachineCraftsman/Atlas 6 inch Metal LatheBuffalo RF-115  4 x 6 inch Band-Saw
Reply:Originally Posted by farmersammFor a 110v machine I favor .030 wire.  For a bigger machine .035 works very well.  I never really liked .045 wire for some reason.  The larger .045 wire doesn't gain you any real thickness advantage, all self shielded wire is limited to 5/16 material in these sizes.
Reply:Originally Posted by wicked4x4wow, the first nazi i've met! thanks for introducing yourself! it's funny, i actually re-read my post and thought someone was going to call me on that typo...and i did not see an 'edit' button to go back and fix it. at least i know i'm not the only grammatically challenged person on this board..
Reply:Originally Posted by DanSam,Lincoln .045 NR 212 and Hobart Fabshield 21B are good for up to 3/4" thick material. Multiple passes of course.