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  • What am I doing wrong? Beginner.

    I am a beginner welder and am starting some welding classes here this month. I have been trying to get ahead of the game and start welding and understanding the basics before I start. I have been practicing on some pretty thick and thin metal and have been getting the same result for a weld. A somewhat tall and skinny bead. What am I doing wrong? Am I going too slow? Not holding at the right angle? Thanks...
    Attached Files

  • #2
    Hard to tell from those pics. If it's a tall bead, possibly too cold, too much wire, too long arc length, or too fast travel speed. Or a hybrid of some of those same factors. Beads will appear a little more raised looking when just burning a bead right on the face of a piece of steel.

    What thickness was that plate? What machine, settings, etc.

    Also, if your brand new that's not too shabby. Pretty consistent, pretty straight. Just keep at it, your class will help as well.
    Last edited by Cgotto6; 03-03-2015, 03:37 PM.

    Comment


    • #3
      Originally posted by Baktc88 View Post
      I am a beginner welder and am starting some welding classes here this month. I have been trying to get ahead of the game and start welding and understanding the basics before I start. I have been practicing on some pretty thick and thin metal and have been getting the same result for a weld. A somewhat tall and skinny bead. What am I doing wrong? Am I going too slow? Not holding at the right angle? Thanks...
      It is worth your while to read the GMAW (MIG) Guidebook to understand the principles and basics

      http://www.millerwelds.com/pdf/mig_handbook.pdf

      The MIG Resources section has a lot of good info and technique videos too

      as well as a MIG settings calculator

      http://www.millerwelds.com/resources...ur-skills/mig/

      http://www.millerwelds.com/resources...calculator.php


      Last edited by H80N; 03-03-2015, 04:44 PM.
      .

      *******************************************
      The more you know, The better you know, How little you know

      “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

      Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

      My Blue Stuff:
      Dynasty 350DX Tigrunner
      Dynasty 200DX
      Millermatic 350P w/25ft Alumapro & 30A
      Millermatic 200

      TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

      Comment


      • #4
        Originally posted by Cgotto6 View Post
        Hard to tell from those pics. If it's a tall bead, possibly too cold, too much wire, too long arc length, or too fast travel speed. Or a hybrid of some of those same factors. Beads will appear a little more raised looking when just burning a bead right on the face of a piece of steel.

        What thickness was that plate? What machine, settings, etc.

        Also, if your brand new that's not too shabby. Pretty consistent, pretty straight. Just keep at it, your class will help as well.
        Thanks for responding... I have a millermatic 211 auto-set. Material I was using was 5/16" thick. Using .035 wire. As far as the settings I went off the chart with 75ar/25co2. I set up my machine to the 1/4" specs. I am running off a standard outlet and not using 230volts, that could be part of the issue correct?
        Attached Files
        Last edited by Baktc88; 03-03-2015, 09:48 PM. Reason: Add Pics.

        Comment


        • #5
          Yes. By running off a 120v outlet you are limiting the machines output to around half. There is no way it will penetrate into a 5/16 plate while running on 120v. Probably a 1/8" limit. Your machine would likely run better with .030 or .023 wire regardless of input power.
          Last edited by Cgotto6; 03-03-2015, 10:04 PM.

          Comment


          • #6
            I'm not able to run .023 with a Miller 252. I did buy a special gun and hose for .023. I haven't tried that. The bird's nests were driving me crazy! TIG is nicer for thin sheet metal anyway.
            Dynasty 280DX
            Bobcat 250
            MM252
            Spool gun
            Twentieth Century 295
            Twentieth Century 295 AC
            Marquette spot welder
            Smith torches

            Comment


            • #7
              bird's nests..??

              Originally posted by WillieB View Post
              I'm not able to run .023 with a Miller 252. I did buy a special gun and hose for .023. I haven't tried that. The bird's nests were driving me crazy! TIG is nicer for thin sheet metal anyway.
              Willie

              something is wrong here... there is no reason your MM252 cannot run .023..just fine

              are you running the correct drive rolls..??

              maybe a tension or liner problem..?? kink in the gun..??

              Arc voltage set too high??... BrandX Contact tips?? (it does make a difference)

              However on the other hand I too prefer TIG for the thin stuff..
              Last edited by H80N; 03-04-2015, 07:37 AM.
              .

              *******************************************
              The more you know, The better you know, How little you know

              “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

              Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

              My Blue Stuff:
              Dynasty 350DX Tigrunner
              Dynasty 200DX
              Millermatic 350P w/25ft Alumapro & 30A
              Millermatic 200

              TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

              Comment


              • #8
                Willie, maybe your gun liner is too large, permitting the wire to kink slightly, possibly in multiple spots which could start a birds nest. You may need to switch liners as well to use .023. I don't use it much but sometimes, if I know I'm working with Sheetmetal for a long time I'll use it.

                Comment


                • #9
                  Originally posted by Cgotto6 View Post
                  Yes. By running off a 120v outlet you are limiting the machines output to around half. There is no way it will penetrate into a 5/16 plate while running on 120v. Probably a 1/8" limit. Your machine would likely run better with .030 or .023 wire regardless of input power.

                  hm alright I will have to pick me up some .030 or .023, just curious why would it run better?! thanks for the replies and helping by the way!

                  Comment


                  • #10
                    Originally posted by Baktc88 View Post
                    hm alright I will have to pick me up some .030 or .023, just curious why would it run better?! thanks for the replies and helping by the way!
                    Old rule of thumb...
                    .023 wire is typically used in applications no thicker than 12 Ga steel and thinner..(.110 inch)
                    not a hard and fast rule but a guideline that many use..
                    .

                    *******************************************
                    The more you know, The better you know, How little you know

                    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

                    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

                    My Blue Stuff:
                    Dynasty 350DX Tigrunner
                    Dynasty 200DX
                    Millermatic 350P w/25ft Alumapro & 30A
                    Millermatic 200

                    TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

                    Comment


                    • #11
                      look at the setup info inside the door

                      Originally posted by Baktc88 View Post
                      hm alright I will have to pick me up some .030 or .023, just curious why would it run better?! thanks for the replies and helping by the way!
                      look at the setup info inside the door---it stops at 3/16" thickness for 120 v. input
                      The settings inside the door will get one close to what's needed.
                      On 120 v. input--need 20 amp or better outlet with short, cord--voltage drop
                      really hammers 120v. machines.

                      Comment


                      • #12
                        Originally posted by H80N View Post
                        Willie

                        something is wrong here... there is no reason your MM252 cannot run .023..just fine

                        are you running the correct drive rolls..??

                        maybe a tension or liner problem..?? kink in the gun..??

                        Arc voltage set too high??... BrandX Contact tips?? (it does make a difference)

                        However on the other hand I too prefer TIG for the thin stuff..
                        I have had a discussion with the roaming troubleshooter at Airgas, and subsequent follow up phone calls. The drive tension, new liner, alignment, depth of liner adjustments have been addressed. He says he will stop in to look it over. The theory is the liner shouldn't be used with .023. I figured it is quicker to replace the whole assembly than a liner, so I bought a new one specifically made for .023" wire. It's funny, it'll run all day until I strike an arc, instant birds nest.
                        I've only experienced birds nest with .030 once or twice when wire sticks to the nozzle.
                        Dynasty 280DX
                        Bobcat 250
                        MM252
                        Spool gun
                        Twentieth Century 295
                        Twentieth Century 295 AC
                        Marquette spot welder
                        Smith torches

                        Comment


                        • #13
                          Originally posted by WillieB View Post
                          I have had a discussion with the roaming troubleshooter at Airgas, and subsequent follow up phone calls. The drive tension, new liner, alignment, depth of liner adjustments have been addressed. He says he will stop in to look it over. The theory is the liner shouldn't be used with .023. I figured it is quicker to replace the whole assembly than a liner, so I bought a new one specifically made for .023" wire. It's funny, it'll run all day until I strike an arc, instant birds nest.
                          I've only experienced birds nest with .030 once or twice when wire sticks to the nozzle.
                          Name brand contact tips of the proper size??.. BrandX stuff can give you fits..

                          a bad spool of wire can drive you crazy too... brand & model??
                          plus... 023 can backlash on the spool very easily


                          are you running the correct drive rolls with matching wire guide??

                          7-4. Aligning Drive Rolls and Wire Guide page 32 of manual

                          http://www.millerwelds.com/om/o230693l_mil.pdf

                          KIT,DRIVE ROLL .023 V-GR 2 ROLL #087131

                          http://www.weldfabulous.com/p-5069-m...gr-2-roll.aspx
                          Attached Files
                          Last edited by H80N; 03-05-2015, 06:54 AM.
                          .

                          *******************************************
                          The more you know, The better you know, How little you know

                          “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

                          Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

                          My Blue Stuff:
                          Dynasty 350DX Tigrunner
                          Dynasty 200DX
                          Millermatic 350P w/25ft Alumapro & 30A
                          Millermatic 200

                          TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

                          Comment


                          • #14
                            You Know me, I drink the Cool Aid. If Miller wanted cheap accessories, they wouldn't trouble themselves to make good ones. This was a major source of frustration on one dump trailer build. I haven't worked it out, but next time it's warm enough I will again address the subject.
                            Dynasty 280DX
                            Bobcat 250
                            MM252
                            Spool gun
                            Twentieth Century 295
                            Twentieth Century 295 AC
                            Marquette spot welder
                            Smith torches

                            Comment


                            • #15
                              I and many here and at WELDINGWEB.COM have found the 211 prefers the .030 wire. Lincoln's L 56 seems to be a favorite among many 211 owners.

                              Comment

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