Help with Welding settings

admin

I was playing with my new Lincoln Power Mig 256 and thought I would see how well it does at high voltage settings.  I don't have the proper gas for Spray Arc but I thought I would see what it will do on 3/16  T-joint at 25 volts/270 ipm.  I am running 75/25 gas at 20 CFM.  I am just a hobbyist so I am still learning everything.  While the sound was different than my normal short arc welding more like rushing air I heard lots of pops during the weld.  Like every second or so I would hear a pop. The weld itself looked pretty good to me. It's fairly smooth and flat and looks to have pretty good penetration.  I included some pictures though the weld looks better live than it does in the pictures with my crappy phone camera.My question is about the the popping sounds during the weld.  It is the gas, the wire feed speed, the volts....  I tried going up on the WFS but I still get popping sounds during the weld.Any help is appreciated. Attached ImagesjohnnyPLincoln Power Mig 256Lincoln 140 HDMiller Maxstar 150 STLHypertherm Powermax 45
Reply:clean the mill scale  before you weld, it will help with spray stability somewhat welds don't look bad but first I would master short arc then try spray which is limited for thickness and position--------------------------------------------------------------www.becmotors.nlyup, I quit welding.. joined welder anonymous
Reply:Originally Posted by Donoharmclean the mill scale  before you weld, it will help with spray stability somewhat welds don't look bad but first I would master short arc then try spray which is limited for thickness and position
Reply:Since you are using 75/25 gas, you are not getting a true spray arc but rather what is called "globular transfer". This means that the molten metal transfers across the arc in large droplets, which causes the popping sound.Also, what diameter wire are you using?  25V sounds high for 270ipm unless you are using .045 wire.Lincoln, Miller, and ESAB all have tons of info on their web sites, including charts of recommended wire speeds and voltage, as well as technical articles describing the various transfer modes. All free to access. Miller even has a smart-phone app.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Axle Spray Transfer 1/8 steel.035 wire @ 320 -340 inches per minute23 to 24 voltsUsing Tri Mix  90-8-2... 90% Argon -8% C02 - 2% OxygenWhen you achieve true spray mode there will be no arc sound at all all you will hear is the hiss of your shield gasThe parameters change as your base metal gets thicker but there is your start The heat and light given off but this process are a bunch try not to melt the end of your gun wear leather and sunscreen because you will get burned on any exposed skin if you do this for any length of timeHave fun with itBacked 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:Originally Posted by Silicon-basedSince you are using 75/25 gas, you are not getting a true spray arc but rather what is called "globular transfer". This means that the molten metal transfers across the arc in large droplets, which causes the popping sound.Also, what diameter wire are you using?  25V sounds high for 270ipm unless you are using .045 wire.Lincoln, Miller, and ESAB all have tons of info on their web sites, including charts of recommended wire speeds and voltage, as well as technical articles describing the various transfer modes. All free to access. Miller even has a smart-phone app.John
Reply:Originally Posted by killdozerd11Axle Spray Transfer 1/8 steel.035 wire @ 320 -340 inches per minute23 to 24 voltsUsing Tri Mix  90-8-2... 90% Argon -8% C02 - 2% OxygenWhen you achieve true spray mode there will be no arc sound at all all you will hear is the hiss of your shield gasThe parameters change as your base metal gets thicker but there is your start The heat and light given off but this process are a bunch try not to melt the end of your gun wear leather and sunscreen because you will get burned on any exposed skin if you do this for any length of timeHave fun with it
Reply:Originally Posted by ZTFabAxle Spray Transfer is when you blow a seal in the differential and it sprays gear oil everywhere..... transferring it all over the underside of your truck. You mean Axial Spray Transfer