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  • apg1984
    started a topic Flux Cores getting me down...

    Flux Cores getting me down...

    I Usally run a millermatic 212 set up with .035 hard wire and a 75/25 argon co2 mix at work. Works great but every once in a while i'll have to run flux core because I'm outdoors. I reversed the polarity, put in knurled drive wheels and put in a fresh liner. Now comes my problems. 1 as I'm welding the wire will just stop feeding. usually with mig i just flick the lead and the wire will pop out. With FC the wire gets all rats nested inside the machine. I loosened the clamp on the wire and make sure I have a new tip but it still happens mid weld instantly. This happens once in a while running mig but with FC it's like every half hour. Any ideas would be greatly appreciated. My other issue is on thinner steel I'm getting holes in my welds. kind of like perosity i guess. When i run mig I can use the same tip all day, FC i'm using about ten.. Is this typical of FC?

  • aametalmaster
    replied
    Originally posted by MMW View Post
    I use v-groove knurled drive rolls for all flux core (with or without gas). It lets you use less tension on the rolls so as to not crush the wire.
    Well today the shop electrician added a longer ground from the 8'3" one that came on the machine. So that let me push the welder back so the gun was straight and i had zero problems it ran like it should have...Bob

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  • MMW
    replied
    Originally posted by apg1984 View Post
    I'm running 035 with a 15' miller lead. Are you suggesting i use a 045 liner with the 035 wire? i have my clamp as loose as it will go thats why i just dont see how its rats nesting so quick... I put a brand new liner in it when i switched to the flux. do you think the knurled wheels are pushing the wire to aggrsively. when i run mig its like you said it will slip and not tangle. its so frustrating.
    No not suggesting that at all. When I run .035 wire in my gun with the .045 liner I do have some problems. The .035 flux wire is not as strong as solid which is why it birdsnests. If you are welding say 1/8" & up material switch to .045. You would also need the correct size liner. In general terms with flux core you can step up a size over solid because there is less material since the wire is hollow. So if you would normally use .035 go to .045.

    What happens is the wire sticks in the tip & the rolls keep pushing so it is birdsnest between the rolls & where it enters the gun. Make sure your wire guide, rolls etc. are all lined up correctly & the gun is as close to rolls as it can be. You can also try anti-spatter spray on your nozzle.

    You also need the spacer to keep the roll of wire tight. It should be a spring but you can even use a pc. of pipe or pvc pipe cut to the right size.
    Last edited by MMW; 03-20-2012, 05:33 AM.

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  • MMW
    replied
    Originally posted by aametalmaster View Post
    Are your drive wheels knurled? I think smooth would be better...Bob
    I use v-groove knurled drive rolls for all flux core (with or without gas). It lets you use less tension on the rolls so as to not crush the wire.

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  • kevin
    replied
    are you keeping the same distance from tip to work as with short arc, fc likes more of a stick out, from all of the fc that i have ran in the past, if i started it with a short stick out, it will burn into the tip, i used about 3/4" for a stick out, hope this helps, my experience was about a 27 years ago welding ships, not to sure if it has changed all that much

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  • S.A.W
    replied
    I have ran fc on my 252 using .035 wire with the u notched rollers and it works great, but from the sounds of it u definitely need the adaptor to use the 10 lb roll, the adapter is basically just a spacer too keep the roll snug to the wall of the machine so the roll can work as intended, I would strongly recommend checking the wire inlet guide, after a while the wire wears it out and it causes the birds nest effect, more so on fc and stainless, if you are using the plastic one that came with the machine I would recommend upgrading to the brass one

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  • go2building
    replied
    Flux Cores getting me down...

    There is a nub on the back of the spool holder, if the spool is not tight to the back it will free wheel and over run the rollers causing a birds nest. I would never run smooth rollers on flux core it will not run with consistent speed, you can not get the rollers tight enough on flux core with smooth rollers with out crushing it and making it out of shape, the reason they don't run smooth rollers on aluminum and flux core!!!

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  • apg1984
    replied
    drive wheels

    I think the Knurled wheels are for a harder wire that
    i'm using. Would you suggest u-groove or v-groove?

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  • aametalmaster
    replied
    Originally posted by apg1984 View Post
    this could be the problem because im running a 10 pound spool. Usually with the hard wire i run 30 pound spools. Am I supposed to have an adapter of some sort? the smaller spool just slides back and forth in the machine.
    There should be a large 2" id spring about 3" long to use with the small 10# spools. I have an extra one if you don't have it...Bob

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  • aametalmaster
    replied
    Originally posted by apg1984 View Post
    its so frustrating.
    Yup i have a brand spanking new MM251 with a 15' gun and i hate it. If it was mine and not the companies i would trade the 15 footer in a minute. I weld in a small area and i can't always keep the lead straight...Bob

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  • apg1984
    replied
    reply

    Originally posted by aametalmaster View Post
    I run gas flux in my MM185 with zero problems but mine has a single wheel drive and a smooth wheel where i think the MM212 has two drive wheels, just not sure...Bob
    this could be the problem because im running a 10 pound spool. Usually with the hard wire i run 30 pound spools. Am I supposed to have an adapter of some sort? the smaller spool just slides back and forth in the machine.

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  • aametalmaster
    replied
    Page 9 has different drive wheels for your machine. I am going to try the mix and match at work tomorrow...Bob
    http://www.millerwelds.com/om/t232385e_pt_mil.pdf

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  • go2building
    replied
    Flux Cores getting me down...

    As far as tips you could have the rollers too tight crushing the wire

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  • apg1984
    replied
    flux core

    Originally posted by MMW View Post
    I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

    What size wire & settings are you running?
    I'm running 035 with a 15' miller lead. Are you suggesting i use a 045 liner with the 035 wire? i have my clamp as loose as it will go thats why i just dont see how its rats nesting so quick... I put a brand new liner in it when i switched to the flux. do you think the knurled wheels are pushing the wire to aggrsively. when i run mig its like you said it will slip and not tangle. its so frustrating.

    Leave a comment:


  • aametalmaster
    replied
    Originally posted by go2building View Post
    Sounds to me like the spool is not locked in to holder or tension is too loose. I never ran flux core in my 212 but with hard wire I have never had it birds nest in the mech. The spool has to be over rolling the feed.
    I run gas flux in my MM185 with zero problems but mine has a single wheel drive and a smooth wheel where i think the MM212 has two drive wheels, just not sure...Bob

    Leave a comment:

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