Question for those who weld..

[Steve P.]

First let me say that I have not welded in many years.    I bought a new Lincold mig welder and I am having some trouble with 2 things.

1) I can't see what I am welding. I am using a gold #11 filter. This is what I used for many years arc welding without any trouble. Now I can't see well enough to run a straight bead. What can I do to rectify this??


2) I don't have a bottle yet, so I am stuck using flux core.  I was welding a new hinge tube on my trailer fender today and I was having trouble with the wire (stepping). I can't think of a better way to explain it. As I was welding the wire was feeding but not burning causing the gun to push back. Then after a split second it would burn and do it all over again. I turned up the power and that helped but then I was burning through.

The welder is a Lincoln Pro-175. 208 volt.  I never welded with flux core before and everyone I have ever heard talk about it says it's a real pain in the ass.. Is this normal for this crap or do I just need to practice more? I should be getting a bottle soon.

[Judhudson]

Hey there,

For the welding helmet, I would recommend an electric helmet.  It's a must in my opinion.  I had so much trouble seeing where I started with one of those flip helmets, as once I flipped it down I couldn't see.  But with an electric, you can see where you start, and once you weld the light from the welding should be enough to see where you should have to go.  Other than that, you might want to switch to a lighter shade.  I'm not positive on the shading numbers thou.

Your second problem sounds like you are losing your ground.  Make sure the ground cable is clamped on good to whatever metal you are working on.

Flux is a pain due to all of the splattering that it causes.

I'm still a newbie at welding, so I have much to learn as well.  Hopefully somebody else can chime in to give you other tips

[73-charger-383]

sounds like a ground problem to me too.....what's your speed at??

[Mopar440+6]

I agree with the above.

1) If money allows get an auto-dark helmet! Where I work I have access to a $900 Speedglass welding helmet/ventilator setup (It's my boss' helmet he just lets me use it if I'm nice to him.) The auto-dark helmets are AWESOME! Im not saying spend $900 on one, the prices have come down considerably. You should be able to get a cheap one for under $150. However at home I have a standard Snap-On (made by Lincoln) flip-up helmet >LINK HERE<. Shade #10 filter since I bought it and have never had a problem with it when welding MIG or ARC.

2) That definately sounds like you are losing ground. Like good bodywork and many other things good preparation is the key to a good weld. Take the time to clean up the area to be welded and where you are planing on connecting the ground clamp to. You don't want any paint or rust in these areas, so time spent with a grinder in your hands will be well worth it in the end.

On a side note:

First off, flux-core wire SUX! The only time I use flux-core is if I have to weld outside where sheilding gas will get blown around. Standard setup for my Millermatic 210 is 75/25 and .030 wire. I have welded everything from 22 gauge to 1/2" plate with this setup.

Secondly, get some sort of an anti-spatter compound. I was recently introduced to the nozzle dip gels. I bought a tub of the stuff and love it since it doesn't burn off like the sprays do.

Sorry for the rant, not trying to sound like I know everything. You guys who do this professionally please correct me if I am wrong. Guess I need to stop spending so much time in the weld shop...

[Steve P.]

I should have mentioned that I thought it was the ground also. I started with grinding a nice big flat spot to connect the ground and the clamp is also brandy spankin.. Not the ground.. 


I was welding at about 3.5 and moved it up to 4. It seemed to be better at 4 and I also made sure the spool drag was not too tight. Yup, I loosened it too much... SPLOOF.........  That was fun with gloves on..

I think I am going to buy a tank tomorrow. I still have more practicing to do before I start on the Coronet. I think part of my problem is my screwed up back. I have trouble sitting in the same position for any length of time. I was a pretty good welder before breaking my back. I think I can pick it up again.. Just have to take a bunch of breaks...   

There is no such thing as taking a break with FLUX CORE.. 

[Todd Wilson]

I should have mentioned that I thought it was the ground also. I started with grinding a nice big flat spot to connect the ground and the clamp is also brandy spankin.. Not the ground.. 

Sounds like the electrode (wire) isnt making a good electrical contact with the surface you are trying to weld. The ground clamp is hooked to nice clean metal but if you cant get the arc to strike its not gonna weld. Might clean up the area you are trying to weld on.  MIG seems to not tolerate poor surfaces  like an good ol Lincoln stick welder. Those things could strike an arc and burn thru what ever and go. Not so with the MIG.


Dont buy a cheap auto darkening helmet. Spend at least 150$ or so for a good unit. The cheaper ones are slower to darken and you wont see it but you will be flashing yourself. A #10 lense should be good enough.


The flux core wire really sucks in general.   Also make sure you have the polarity set right for the kind of wire and gas you will be using. That can make a lot of differnce! ON my Hobart I can switch + or - for the ground or gun.


Todd

[Steve P.]

I hear ya Todd.. It's strange that it was pushing off and not welding constant. The metal I was welding is new and very clean. I ground it myself.

I have a MILLER arc welder. It will weld through anything.. 

I have been looking at a cheaper auto-darkening helmet. It's a Hobart and it says it darkens within 1/17000 of a second. $69.00 at Tractor Supply Co.  It isn't in their catalog, but they have 2 left in the store.

Do the lens numbers go up for darker. I can't remember... I have welded a few very straight lines that didn't put 2 pieces of steel together.. Hahaha... It sucks not being able to see.. I swear I used to be a good welder. I did more stick than mig though. Boiler plant stuff...

Oh yeah, I do have to swap polarity when I go to gas if I remember correctly... I'll check inside the hood.

Thanks guys..

[73-charger-383]

We have a welder at work that acts up every once in a while.  The problem is the plug.......when the feeder does exactly what you are explaining, the problem usually that it's running on 110v.  You go twist the plug a little and it works fine.   -So, you might wanna make sure your breakers aren't tripped and be sure your at 208.
that's about all i can think of if your ground is clean.

[Steve P.]

Good point.. I will check it out again. I didn't build the welder so if that is the problem it will be going back. I made up the extension and put all the electrical in the shop. I am kind of anal when it comes to electricity. That doesn't mean a breaker can't be weak.. 

I'll plug in my stick welder and burn a rod. That will tell me for sure if it's electrical out as far as the end of the cord.

Yes, I made a monster extension cord for both. 25 feet long. That will get me out of the shop into the driveway..