Lincoln Innersheild Fluxcore Wire

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Just realised ( idiot me), I've been using .035" wire in my Fluxcore Welder and the spec. says use .030".      Thinking back to the first roll of Lincoln wire I loaded up, it felt tighter, but fed through ok and produced good (for me) clean results, if I did my part.Today, got my Welder exchanged for a new one (90AMP Fluxcore) , made sure I had my Reading glasses and went to Home Depot to get some Lincoln Innershield .030" ,  ----As Specified.Fed in much easier (what a surprise eh !).Question is , would the .030" wire be more prone to spatter, or is it, I now have to learn the charcteristics of the smaller diameter wire.  Feed rate settings , stick out etc. ?I'm very much the little experienced amature, but really enjoy the whole metal working hobby.I almost went back up the road to get a roll of .035"  but thought I'd seek guidance from those that really know.Thanks all.
Reply:Question is , would the .030" wire be more prone to spatter, or is it, I now have to learn the charcteristics of the smaller diameter wire. Feed rate settings , stick out etc. ?
Reply:Settings will be different, but you will figure that out in a short amount of time.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Thanks folks, back to bead practice I guess.
Reply:My little 88 amp Lincoln came with NR211-MP in .035. I've had it a couple of years now and have had no problems with it. I've never seen the Lincoln wire in .030 that I can recall.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Originally Posted by Jolly RogerMy little 88 amp Lincoln came with NR211-MP in .035. I've had it a couple of years now and have had no problems with it. I've never seen the Lincoln wire in .030 that I can recall.
Reply:Per a Lincoln operating parameter table, 0.035 NR-211MP runs from about 14V at 50 ipm and 30A, to 15V at 70 ipm and 60A, to16V at 90 ipm and 90A, to 16.5V at 110 ipm and 120A.That seems to cover the range pretty well for most of the small 120V FCAW machines.AFAIK, the 0.030 FCAW will give you a little lower amps for the same voltage and wire-speed compared to the 0.035 wire.For small machines, either one will most likely work OK.  The parameters will run slightly different between the two wire sizes, just like any wire-size change would do.More importantly, make sure you have the right size contact tip in the torch for the wire diameter.  0.035 wire really doesn't fit through an 0.030 contact tip.And make sure you have a compatible drive roller in place for the wire diameter.  The 'older' 'small' Lincoln's seem to have a drive roller with a small groove for 0.023/0.025 wire, and the slightly larger groove for 0.030 and 0.035 wire.  The new PM140 has an 0.025/0.030 drive roll and an 0.035 drive roll.  Check your manual to make sure you have the right drive roll for the wire diameter.  Also make sure you don't have too small of a diameter liner in the torch.  Using 0.023/0.025 wire in an 0.035 liner works OK.  Trying to run 0.035 wire through an 0.025/0.030 liner doesn't work so well.
Reply:Originally Posted by RetiredoneHome depot carries it, for some reason, it's just over a Dollar more expensive than the .035"for the 1Lb reel.
Reply:Interesting info. MoonRise, yet another reminder of how little  I know. Appreciate the info. though.  Reset my wire speed from 6 to 8 since using the .030".  Less than that and I seemed to producing a lot spitting(splatter).On the the wire pricing, had some fun with the Guy in that Dept.at Home Depot.   I asked ,why are they charging more, for the same weight of wire ?,  ---Hmmm , don't know he said.    To add insult to injury, I added, it's even THINNER !!.Poor guy looked at me perplexed,(we know each other,--always yanking each others chain).     Anyhow, thanks again folks. Great info.
Reply:Pricing is the same way on electrodes. The smaller the diameter the higher the price per pound. I don't buy anything smaller than 10lb spools. Never even look at the small ones. I sometimes go through 25lbs in 2 days.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Food for thought...You mentioned that you changed the wire to .030" from .035"...did you also change your contact tip to .030" from .035"?That may be the cause of the spatter....http://all-a-cart.comWelding Cart Kits and accessories
Reply:Altho only .005" difference in diameter it is a difference none the less. That small difference in cross sectional numeric values also equates to a difference in arc density which affects the way it performs and 'feels' which isn't one of the charactersitics that can be practically listed on a simple amps 'n volts type of chart. Bottom line try it, if you don't like it the .035 will still be in production.
Reply:Originally Posted by ZTFabFood for thought...You mentioned that you changed the wire to .030" from .035"...did you also change your contact tip to .030" from .035"?That may be the cause of the spatter....
Reply:Originally Posted by TEKZTFab, a lot of people here like to say that you should use an oversize tip, that it doesnt matter if its correct to the wire....I have said otherwise but, well, you know.....So, which camp are you in?....and, tell the kids why
Reply:Thank you.....
Reply:The increased cost is most likely due to the additional time, energy, dies needed to draw the wire out additional times to get it smaller. -DanOwnerDW Metalworks LLCMiller Trailblazer 302Miller 8RC FeederMiller Passport PlusMiller Dynasty 200 DX W/Coolmate 1Hobart Handler 135Hypertherm PowerMAX 30Smith O/A Torch SetPlus much much more
Reply:Originally Posted by ZTFabFood for thought...You mentioned that you changed the wire to .030" from .035"...did you also change your contact tip to .030" from .035"?That may be the cause of the spatter....
Reply:Originally Posted by RetiredoneNo, as I mentioned earlier, I must not have had my Glasses or wasn't paying attention.The .035" felt   a bit snug, but fed through without issue.  Tip was marked 0.9mm.Now I'm back (0.9 tip) on .030" wire, I can certainly feel the clearance.    The spatter issue was resolved by increasing my feed to 8 on the dial (set on 6 with the .035").I guess with a low power unit like this one, a thinner guage (.030")  would provide a more acceptable performance?
Reply:Yes it is.   Supplied wire with the Welder is .030"  (0.9 tips).Been using .035 " with no problem , even though the Harbor Freight Instruction book says use .030".I guess in my ignorant state, I, ------- dare I say it, "assumed" that a clearance factor was involved.Should I use .035" with a 0.9 tip ?
Reply:0.030 inch = 0.8 mm0.035 inch = 0.9 mmSmall 120V FCAW machines can -usually- run either size FCAW wire.  But no bigger.  The next size up is 0.045, and that is really in the realm of the 180A-240V machines or better.For solid (GMAW, aka MIG) wire, the small machines can -usually- run the 0.023/0.025 or the 0.030 plain wire.  With gas, and the polarity reset, etc, etc.  YMMV.As I posted above, the operating parameters for Lincoln NR-211MP in 0.035 size fall pretty well in the range of (most?) small 120V FCAW machines.  The 0.030 size would need a bit more wire speed compared to the 0.035 to be in it's 'sweet-spot', as you found out when you had to boost the wire speed from 6 to 8 when you changed to the smaller diameter wire.Try the different size wires and see what works for you and your machine and your application(s).  But it is better (best) if you do match the tip size to the wire size.  And there is enough of a difference between 0.030 and 0.035 (~15% in diameter) that they really are two different size tips and wires (and maybe drive rollers, depending on the roller groove geometry).And to decrease spatter (in order of importance):1. Adjust voltage2. Decrease drag angle3. Decrease CTWD4. Increase WFS5. Decrease travel speed  The best laid schemes ... Gang oft agley ...
Reply:Thanks again MoonRise, great info.Now I'm really going to show my ignorance,----get ready to cringe !What is CTWD and WFS ??
Reply:Go to the Lincoln or Miller or ESAB websites and read up on all sorts of info about welding.www.lincolnelectric.comwww.millerwelds.comwww.esabna.com  (for North America, if you want another region just hit esab.com and click the map for where you are in the world)WFS = wire feed speedCTWD = contact tip work distance, ie the distance from the end of the contact tip to the work piece as you are welding, aka 'stick-out'Most of the 'little' wires and the little machines and their operating parameters call for a 'stick-out' of about 1/2 inch, give or take.  So, as you are welding, you should keep the end of the contact tip 1/2 inch away from the work piece.  Too much stick-out and the arc heat is reduced (useful when you hit a thin spot or gap on the metal you are welding, you pull the torch back -slightly- and the arc loses some ooomph).  Too close and you coat the tip end with spatter quickly or melt it or jam it into the workpiece and short out the gun and stick the tip to the workpiece.  The best laid schemes ... Gang oft agley ...
Reply:Thank you . I'll read those links you posted.
Reply:I'm not ZTFab but I also recommend using the right size contact tip for the wire size being used. It should fit snug on a new tip, but it won't be after a while. I run a lot of flux cored wire (bare wire as well and this is true for it as well). Contact tips wear out. The hole enlarges and once it hits a certain point it starts to stick in the tip. This is caused by arcing inside the tip. You can use the larger tips, you just won't get as much use out of them before they must be replaced. With the price of copper it doesn't take long for it to start to add up.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Jolly Roger, thanks for the input. I think people here still respect your opinions....I know with me, I can feel a distinct difference in the puddle characteristics when I put a new tip in. A much more stable puddle and more control......I am one that sez use a bigger tip at times.  Those times are for pulsed spray or spray welding especially for aluminum.  When getting into to those heat ranges (200 amps and up), the wire pre heats and expands before it gets out of the contact tip.  It can and will bind. For short circuit, use the correct size tip for the wire like said above.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:IMO, you should use the proper sized tip for fluxcore.  You can certainly get away with using a larger sized tip, but your arc will not be as nice.