any advice on reducing mig spatter balls???

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I'm doing a job welding 3/16 1018 carbon with thru hole to 1\2 1018 shaft. I'm using mig with s6 .30 wire, 75/25 gas and anti spatter spray. I cannot get ride of hot balls. CAN ANYONE HELP?? Attached ImagesMiller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Try standing further back from the table!!Sorry, couldn't resist it."One of the things we have to be thankful for is that we don't get as much government as we pay for." (Charles Kettering)Mitch 180 (NZ)Lincoln SAM-400-220 + ?-400 Fordson Major + 2 x Tractapac Humber 80 + Procut 40 PlasmaMiller Spectrum 375
Reply:I would try a 92/8 (Argon/Co2) or preferably a 95/5 (argon/oxygen) for a real nice spray transfer with good wetting to avoid the spatter.
Reply:I agree with the recommendation for 92/8 Ar/CO2 and spray transfer.  With somewhere over 15% CO2 you cannot achieve a pure spray transfer.  The 75/25 you are using is good for low spatter short arc tranfer MIG, but you may be pushing higher current and voltage and be in the globular transfer mode.In short arc mode, the power supply voltage/current slope and inductance can help reduce spatter.  See this ESAB link for an explaination:  http://www.esabna.com/EUWeb/MIG_handbook/592mig3_3.htmIf your machine does not have slope or inductance adjustments/settings, you can try increasing inductance by wrapping the work cable several times around a chunk of steel.  The more wraps the higher the inductance.  Inductance slows down the rate of rise of the short circuit current and helps limit the spike of current that blows off the molten end of the wire into spatter.
Reply:Originally Posted by TractapacTry standing further back from the table!!Sorry, couldn't resist it.
Reply:I may possibly have a remedy for your problem however I have not had too much experience welding material under 1/4 inch thick with the procedure I am thinking of. With a standard GMAW machine (Amp and Volts settings only) I have used Lincoln's Cored Outer Shield wire, Ultra-Core 712C and reduced amost all secondary operations as far as is spatter is concerned. You have to use 100% CO2 and short circuit. But for what I was welding it made a Multiple pass welding job a breeze. High deposition and next to no spatter is a real plus with a non state-of-the-art machine. I do not know how it would work with your 3/16" material but it may be worth a try. 045" dia. is within working range with 3/16" thick matreial. Also other cored 70 series wires may work just as well, but the 712C is what I am familiar with.Once amps are set you can adjust voltage to keep spatter to a minumum.Hope this helps.
Reply:Originally Posted by TractapacTry standing further back from the table!!Sorry, couldn't resist it.
Reply:Troubleshooting:---------------Spatter: -------wire feed too high : lower the wire speedvoltage too high : lower the voltageCTWD/stickout too high : use shorter stickoutdirty workpiece : clean workpiece before weldinginsufficient shielding gas : increase gas flow and/or prevent draftsdirty welding wire : use clean, dry wire; clean the feeder or linerSometimes the voltage just needs to be dropped a half volt or so, for 'fussy' work or welders that's where a continuous-control machine is nice compared to a tapped-machine.If the voltage is a bit too high, you could also be getting globular transfer (as mentioned).  You aren't going to (realistically) get into spray transfer with C25 gas, you could go with an argon-oxygen (standard 98-2) mix or an argon-CO2 mix with the CO2 below 15% (also as mentioned) like a C-12 or C-8 mix.Since your job there is the plates-to-rods, just knock off the spatter with a tool when the welding is done.  Grinder, flap-disk, cold-chisel, chipping hammer, some combination of all of the above.  The best laid schemes ... Gang oft agley ...
Reply:I don't have a 98/2 bottle at the moment. What would happen using pure argon? I'm going to LWS tomorrow. What would be the best gas, 98/2(argon-oxy), 98/2(argon-co2). And I am not familiar with 95/5??Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Originally Posted by 59halfstepIf Denrep has any of that hide left one could make "leather cup".
Reply:I don't know.. but I would say wire speed is too fast....
Reply:Don't use pure Argon...Here is something that may help and i have used it while welding multiple parts like yours. The little balls on the parts you are not welding are getting stuck from the part you are welding. Like bouncing off and sticking to the other parts. So cut some little metal shields about an inch high and shape them to fit around the part you are welding, spray some anti weld splatter on the parts and weld away. Its worth a try. Then move the sheild to the next part. I had the same problem when doing multiple setups with my ornamential iron work...BobBob WrightSalem, Ohio  Birthplace of the Silver & Deming Drillhttp://groups.yahoo.com/group/southbend10k/http://groups.yahoo.com/group/sawking/1999 Miller MM185 w/ Miller 185 Spoolmate spoolgun
Reply:Originally Posted by waginWhat?
Reply:The 95/5 with argon oxygen is a popular gas in Southern Ontario, I'm not sure if it is used in the US very much because I have posted it several times on here and nobody seems familiar with it. It will not have as good penetrating abilities as the 92/8 with argon C02 but it does allow for good wetting and allow the bead to lay flatter then the argon/C02 blend will. I find that it will go into a true spray transfer with lower wire speed and voltage settings then the 92/8 argon CO2 does.  For one production job that I do I have certified the procedure with this gas, it works very well as the beads lay flat, no spatter and it leaves very little for the grinders to blend the welds flush as required. This is an x-ray job as well and I get few defects. I think any gas that will get you into a true spray transfer will get you the results you are looking for though so the 92/8 argon CO2 blend will work fine as well.Regards and good luck