I knew Flux Core was messy, but...

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K guys, picked up my Clarke 130EN package on sunday and tested it out today (will have separate thread with pics and all)Anywho, I picked up some plain steel to practice some beads and joints on, and I couldnt seem to get the right welds.  Check out this picture...I adjusted the wire speed a few different times and it didnt seem to help much.  There is a flat steel bar lying down, then a straight up one with a t frame.  The top part of the T already broke off.EDIT: More pics:Here is the underside, apparently I penetrated pretty good:Please let me know any ideas you have for me to try.  Different temps, speeds, or preparation.Thanks!Last edited by redhatman; 04-16-2007 at 10:08 PM.I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:try chipping off the slag
Reply:Originally Posted by terr1bleonetry chipping off the slag
Reply:You said plain steel wire.  What # is the wire?  Electrode posative or Electrode negative?  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:It is 0,9mm I think, its flux cored steel welding wire.  Came with the Clarke.I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:do you have the polarity right for the flux core setup, also are you sure its the right wire, almost looks like mig wire to me.
Reply:Adjust your wire speed way down from where you have it.From the looks of it, I'll bet you were getting a lot of "popping" and sputtering while you were welding.Just keep adjusting it until you get a smooth arc.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:He's in the chat and says it is set up for flux, according to his instruction book. Hey Paul !John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Hey John!!I've found that the 110 welders like a really slow wire speed when running with flux.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Cool, thanks guys.  The lowest speed I went to was 2.5/10 however, that was at max heat 4/4 settings.  I will play around with it more tomorrow.I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:As another suggestion, you might want to clean the metal a bit more before welding on it.  Looks like you got a chunk of sheet from a home center (I get some of mine there too).Sometimes there's a coating on the metal that needs a little more cleaning, even with flux core.Grab a grinder with a flapdisk or knotted wire brush on it and go to town.Keep at it and you'll get it.
Reply:whow.... thats some pretty nasty welds!!!looks like you're going to have to put a few more hours into it. Here's one i did really quick in my basement, no metal prep.... mid(4) wire speed, max heat. Last edited by ThunderRobo; 04-17-2007 at 03:37 PM.-Clarke 130EN-Miller MaxStar 150STL-Miller Elite 29' Roadster
Reply:it's hard to get a focace -Clarke 130EN-Miller MaxStar 150STL-Miller Elite 29' Roadster
Reply:Can't see it - need a bigger picture. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by MicroZoneCan't see it - need a bigger picture.
Reply:Cool, thanks thunder.  I am going out again to try some more.  Did you do any prep on that steel?  Also, what were the "guess-a-mated" mystery settings?I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:Originally Posted by redhatmanI am talking about the welds.  They seem crappy, not a steady line although I held the tip straight. There is also a big mess of slag, which I understand.
Reply:Ok guys, I tried it more today and not too much better luck.I tried to join some 90 degree metal (16 gauge) and it worked alright, but the welds consist of balls more than making it one piece of metal all joined together.  The same happened when I tried joining two rods.I did manage to get a really nice line on the 16 gauge, using the lowest power, and like 2/10 wire speed.  I could tell it was too cold of a weld because it was skinny and kinda tall. I really tried most of the things today, without much luck.  Is this because of flux core, or do I just have to learn?  The other time I welded was with gas, and I did fine, maybe it was luck?Please let me know your tips/tricks.  I would go to gas, but thats at least another $100, unless I were to lease a tank.  I think my next purchase will be a autodarkening mask.I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:Originally Posted by redhatmanOk guys, I tried it more today and not too much better luck.I tried to join some 90 degree metal (16 gauge) and it worked alright, but the welds consist of balls more than making it one piece of metal all joined together.  The same happened when I tried joining two rods.I did manage to get a really nice line on the 16 gauge, using the lowest power, and like 2/10 wire speed.  I could tell it was too cold of a weld because it was skinny and kinda tall. I really tried most of the things today, without much luck.  Is this because of flux core, or do I just have to learn?  The other time I welded was with gas, and I did fine, maybe it was luck?Please let me know your tips/tricks.  I would go to gas, but thats at least another $100, unless I were to lease a tank.  I think my next purchase will be a autodarkening mask.
Reply:Sheet isn't that hard to weld but not the best to learn on. If I were you I'd get some 1/8" or 11 gauge steel and turn the machine up. You might find that the sweet spot might be a bit wider when your not trying to use the lower end of the settings. It will be easier watch the puddle flow with the thicker metal. Once you got this down pat you'll move on to sheet metal with little problem.
Reply:Originally Posted by redhatmanCool, thanks thunder.  I am going out again to try some more.  Did you do any prep on that steel?  Also, what were the "guess-a-mated" mystery settings?
Reply:Now you have to do it upside down on your back on sheet metal.. ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:or like this cccccccccccccccccccccccTrailblazer 302 AirpakDynasty 200 DX  Thermal Dynamics Cutmaster 52 CamoMiller Dailarc 250 OLD But great!!2 Miller 140's w/autoset NEW! Millwauke Cold cut sawsDewalt portabandJd2 notcherPipe beveling machine
Reply:or maybe even like this /\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\/\-Clarke 130EN-Miller MaxStar 150STL-Miller Elite 29' Roadster
Reply:^^^^^ While your upside down on your back... ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.looks to me as stated before wrong polarity! Check your machine.
Reply:Yea, i agree with the reversed polarity issue, post some more pics!-Clarke 130EN-Miller MaxStar 150STL-Miller Elite 29' Roadster
Reply:Hi Redhatman, Forum newb here, how ya' doin'...what they said check polarity to make sure, and your welding tip must be making little circular O's or stitched V's to make a little puddle as the molten wire penetrates and joins the pieces together.  All that popping and spatter is too fast a wire feed, not the flux (flux will cause a little spatter.) OOOOOOOOOOOOOOO  or  VVVVVVVVVVVVVVVVVNot a straight line -------------------------I'm still working on updside down and backwards too  .
Reply:A lot of guys say you ned a better quality of flux wire. You may wan to try that. It's under $20.00 for a spool. Might be worth a try?