Help newbie with new mig welder

admin

Hey gang looking for some direction here.......I purchased a new 255MM and used 30a spool gun but I am struggling with a soot problem.I know its likely something I am doing wrong so I hope I can get some suggestions.I am sure there are many problems (this is my first attempt with a mig welder so lots to critique ) but mostly concerned with all the soot and I believe its a gas coverage problem but....I have changed out both the argon tanks and swapped regs with the ones from my tig welder I know to work fine.I have tried from 20cfm to 35cfm and really no different results.Material is 6061 1/4" thickWire is .030 5356Machine auto set / pulseI prepped with a ss wire brush no differently than I would have if I was going to tig weld it.I am curious with similar gas flow from my tig torch I rarely hear the gas flowing from the nozzle but on the spool gun its very noticeable. does this sound normal?I have ordered a new diffuser and nozzle but probably won't get them till next week to try.

Attached Images



Lincoln Squarewave 255Miller Coolmate IIISpeedway 320Lots of melted mess so far
Reply:Welcome to the group  Dave

Originally Posted by Sr SQ

Hey gang looking for some direction here.......I purchased a new 255MM and used 30a spool gun but I am struggling with a soot problem.I know its likely something I am doing wrong so I hope I can get some suggestions.I am sure there are many problems (this is my first attempt with a mig welder so lots to critique ) but mostly concerned with all the soot and I believe its a gas coverage problem but....I have changed out both the argon tanks and swapped regs with the ones from my tig welder I know to work fine.I have tried from 20cfm to 35cfm and really no different results.Material is 6061 1/4" thickWire is .030 5356Machine auto set / pulseI prepped with a ss wire brush no differently than I would have if I was going to tig weld it.I am curious with similar gas flow from my tig torch I rarely hear the gas flowing from the nozzle but on the spool gun its very noticeable. does this sound normal?I have ordered a new diffuser and nozzle but probably won't get them till next week to try.
Reply:hello right back at you.  I've used my 30A for both 4043 filler and 5356 filler.  Pushing the puddle I've noticed that the 5356 filler will make more soot and required brushing to remove it and all was well.  It will take hood time to get the feel for the machine and maybe a little bit of fine tuning.  The only thing I can say is ... It's a dance.  Have fun and stay safe.
Reply:Two things. Check with the wire manufacturer for recommended gas flow. Lincoln recommends 30-50 CFH for their 5356 wire. I suspect you will need significantly more gas than you are using now. Second, are you pushing the weld or pulling? You will always get soot if you are pulling the weld. You need to use a push technique.Miller Multimatic 255
Reply:Soot/smut from the magnesium burning out of the spray transfer arc when using 5356 comes with the territory. The pushing of the torch directs the arc into the root pulling out the smut allowing a sound fusion. A high enough amperage ensures cleaning at the toes as the puddle progresses, and you should not have to stop to clean smut. The higher the amps, the more mag smut. On the plus side the mag has an exothermic benefit to it burning out of the spray and what it left reacts to the base metal for effect. 4000 series wire has much less smut to deal with. Get yourself a few brass or bronze toothbrush style wire brushes. clean and move on. But don't leave that smut too long or it will react to the atmosphere and harden up making it harder to remove. https://www.mcmaster.com/7327T22/Weld like a "WELDOR", not a wel-"DERR"

MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:add some helium Sent from my SM-N975U using Tapatalk
Reply:

Originally Posted by neilkingent

add some helium Sent from my SM-N975U using Tapatalk
Reply:

Originally Posted by neilkingent

add some helium
Reply:Ok thank you for all the replies Yes all the welds were pushed.I hope to get the new parts for the gun today or next and will try out with higher gas flows.Thank you for the tip on the wire size, I looked for a chart with recommendations and really never found anything.Lincoln Squarewave 255Miller Coolmate IIISpeedway 320Lots of melted mess so far
Reply:5356 soots no matter what you do. I have tried using the largest nozzles with 50 cfm of argon. Nothing helped. If you want clean 5356. Tig weld it.
Reply:Ok, little update......Moved up to some 3/64 4043 wire and upped the gas flow to 40cfm and quite a bit better.I still have a bit initially but it cleans up nicely.I appreciate all the help

Lincoln Squarewave 255Miller Coolmate IIISpeedway 320Lots of melted mess so far