1/4" to 1/4" weld questions

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Sorry for the lame question.  So many variables to this I couldn't think of any way to search for this answer(s).I'm new to this. I'm not getting enough penetration.  No!! That kind is fine ask your GF ....   The welding kind is my question.   Have only used Flux core up to this point. Mig Welder is finger touch variable wire speed (a trigger on a portable welder)Volt and amps is controlled somewhat by wire speed and number of batteries I wire up.  Been using 24v but have access to another battery to make it 36v sooooo...... question isTo get good penetration on both pieces:1. 1/4" thick (scrap 2x4 channel) 2. 1/4" thick tube (scrap 2.5" tube w/close to 1/4 wall  [3/16?]); Both typical iron type medal, I should use:*Wire w/ gas or Flux Wire?--- what wire?----if gas-what gas ratio's?-----24v or 36v?------If adding gas is best will the cheap regulators that came with my O/A torch work or will I need different ones?Flame suite on   and THANX in advanceLast edited by coachgeo; 07-10-2006 at 01:21 AM.
Reply:Sorry didn't mean to confuse everyone.  Here is what I tried. . 24v. 0.35 flux core wire. GAS at 15 /indoor/No wind. Wire speed -as fast a speed as I could without the wire pushing back on the gun. (kick back?) The results were better penetration on the tube and no better penetration on the channel Iron (the thicker and larger of the two pieces)  Now I got one hell of mess to grind off the tube before I can try it again  Why did I do the above? The manual of the welder in a nut shell says..... * Amperage = heat = more penetration.  ???Makes since right?*Thicker wire = more availalbe amperage being transmited to the metals being joined, thus more heat, thus more penetration.  ????Sound right?*Use Fastest Wire Feed possible= more continuos of available Amperage being transmited, thus more heat, thus more penetration. ????Sounds good to me. You?*Gas is used to provide the cleanest weld environment possible (less impurities)   *Flux- simular to gas???? Any arguments there?Thus I used gas AND flux to get the Ultimate in cleanest weld environment and the thickest wire I could get to fit my tips which is Flux 0.35 wire. I also used a steady wire feed that didnt kick me back or cause the electrical charge to break betweent the wire and the surface. Next I'll try the same as above but with 36V. Won't this push the available amps higher? If so then; if I have the theory right, this should allow faster wire speeds, thus more amps/heat being pushed into the channel Iron resulting in better penetration.  I have checked and the tips are same as those used in 220V guns. PS- areas to be welded are bare shinny metal surround be surface rust and/or paint.  Ground is on the channel Iron ,on bare shiny metal.Last edited by coachgeo; 07-11-2006 at 01:19 AM.
Reply:Gotta pic? Makes it easier to see exactly whats going on.
Reply:I'm not familiar with the welder your using but mig wire and fluxcore wire run on different polarities. Fluxcore wire runs DCEN. Have you tried switching polarities?
Reply:Originally Posted by spuddownI'm not familiar with the welder your using but mig wire and fluxcore wire run on different polarities. Fluxcore wire runs DCEN. Have you tried switching polarities?
Reply:just did a quick search to clarify my thinking.  Now not sure if I read this right or not.  Yeah I feel stupid. This is from Hobart websiteDirect Current Electrode Negative (DCEN)-The specific direction of current flow through a welding circuit when the electrode lead is connected to the negative terminal and the work lead is connected to the positive terminal of a DC welding machine. Also called direct current, straight polarity (DCSP).to simplify:Work lead is the ground clamp  Electrode lead is the welding wireright?Again the question remains is the only reason you do the two differently (DCEP, DCEN) is that one produces less splatter (DCEP) than the other or is there more to it than that? Im sure there is more to it.  Thinking about it maybe less splatter means less amps being pushed? Learning as I go.Last edited by coachgeo; 07-11-2006 at 08:02 AM.
Reply:what kind of gas where you using? CO2, argon, a combination?running a smaller wire (23 instead of 35) should give you a little more penetration (same amperage being focused into a smaller contact point). use straight CO2 with it (for better penetration). "work lead is the ground clamp, and electrode lead is the wire?" yes.before you go out and buy more wire and gas, try and upload pics as someone may just see a problem with the setup. and it will give others a chance to correct me (or add more/better info) if its needed
Reply:Originally Posted by LuzRDwhat kind of gas where you using? CO2, argon, a combination?
Reply:Well Iza got some bad news and some good news.  Bad news is I can't take pictures. My camera is broke.  Two pins bent yesturday while putting in the memory card. Good news.  I got LP and O2 for cutting with my torch and cut off the old welds from the tube so I could start over.  Being a fumble fingured newbie I melted a chunk off the tube itself too. Realy butchered it. Cleaned it all up best I could and welded to the channel Iron anyway.  Obviously that is not the good news. Anyway... At 36v the thing welded like MADDDD.  Penetration was awsome.  It was welding so nice I laid in a few beads atop each other and filled my snafu like I was laying beads of caulk.  Came out ok in the end.
Reply:glad to hear it (the good news part anyway)