What am I doing wrong? Beginner.

[Guest]

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...

[Cgotto6]

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.

[H80N]

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/improving-your-skills/mig/

http://www.millerwelds.com/resources/calculators/mig_solid_amperage_calculator.php

[Baktc88]

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?

[Cgotto6]

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.

[WillieB]

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.

[H80N]

bird's nests..??

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..

[Cgotto6]

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.

[Baktc88]

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!

[H80N]

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..

[dave powelson]

look at the setup info inside the door

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.

[WillieB]

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.

[H80N]

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-miller-087131-kitdrive-roll-023-v-gr-2-roll.aspx

[WillieB]

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.

[BD1]

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.