Can anyone figure out what is wrong with my welds? :confused:

[mi_r16]

Hi y'all! I would really appreciate it if anyone could tell my what is up with my welds. I can not figure out what causes the welds looking like this. All the beads in the pictures have different wire feeding speeds, amps and gas flow settings, but it does not seem to get any better. They are really pourus all the way through and it sounds (and looks) totally wrong when welding. I use co2 shielding gas and a spool of SG-2 AWS A5.18:ER70S-6 wire (or at least the sticker on the spool says so). If there is anything I forgot to mention please don't hesitate to ask. This is making me crazy.

Thanks

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[Fat-Fab.com]

Hi y'all! I would really appreciate it if anyone could tell my what is up with my welds. I can not figure out what causes the welds looking like this. All the beads in the pictures have different wire feeding speeds, amps and gas flow settings, but it does not seem to get any better. They are really pourus all the way through and it sounds (and looks) totally wrong when welding. I use co2 shielding gas and a spool of SG-2 AWS A5.18:ER70S-6 wire (or at least the sticker on the spool says so). If there is anything I forgot to mention please don't hesitate to ask. This is making me crazy.

Thanks

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Machine settings and polarity Gas flow settings, machine type please?


With out that knowledge my guess is too much stick out (the tip out passed the end of the gas nozzle) and or the tip too far from the work


Might also be a gas flow problem not enough too much or a leak in the line sucking in atmosphere.

[fabricator]

also, what is the exact amount of gas/gases in your bottle?

[john p]

bad weld

Could be starting with gas ,I use a mixed gas C-25.Weld were there is no cross draft ,mig welding needs gas.Make sure gas hose is good and check for leaks or kinks.Clean base metal very good and also the ground connection ,very important.

[mooseye]

What kind of metal are you welding on?
My first thought is too much heat and too fast of wire feed if that is clean bare steel.
It looks very thin also. If you use too much heat, could be burning thru and pulling atmosphere from bottom.

[Broccoli1]

also, what is the exact amount of gas/gases in your bottle?

That would be a tough one as he would have to weigh his jug, know what the original weight etc. and CO2 can show pressure right up until it goes empty.

[JCFab]

I've seen the "volcano" at the end of the weld before at work. It turned out to be a bad nozzle seal. It was sucking air past the diffuser and mixing with the shield gas. Mill oil on the steel has done that to me at home also.
Jeff

[mi_r16]

Machine settings and polarity Gas flow settings, machine type please?

Sorry to say it's no Miller or other high quality welder. It's a SIP Migmate 150 230volt.
It has negative ground.
I've tried all possible settings on the welder with just the same result. It has just hi/low and max/med/min for amps and fully adjustable wire feed.
As for gas flow i've tried everything from nothing to max, and the weld is basically bad no matter what flow.

I have been welding with this welder for years with no problems what so ever. It's just this last year or so it's been acting up. For long I just thought the metal I was welding were too dirty. But the other day I had to weld something air tight and cleaned it off really good, but still same crappy welds.

With out that knowledge my guess is too much stick out (the tip out passed the end of the gas nozzle) and or the tip too far from the work

I'm pretty sure I have it close enough.

Might also be a gas flow problem not enough too much or a leak in the line sucking in atmosphere.

Would'nt a leak just cause the co2 to leak out instead of sucking atmosphere in? Anyways I found no leaks in the line.

also, what is the exact amount of gas/gases in your bottle?

I use disposable bottles with pure co2.

Could be starting with gas ,I use a mixed gas C-25.Weld were there is no cross draft ,mig welding needs gas.Make sure gas hose is good and check for leaks or kinks.Clean base metal very good and also the ground connection ,very important.

There is no draft in my shop, and I've tried sandblasting, wire brushing, paint thinner, etc to clean the metal. No difference

What kind of metal are you welding on?

Not sure exactly the type of metal I welded on in the pictures, but I've tried several types I found laying around my shop and there is just the same problems with all. Although the 316 stainles steel pieces I tried on the weld bead looks better.

My first thought is too much heat and too fast of wire feed if that is clean bare steel.
It looks very thin also. If you use too much heat, could be burning thru and pulling atmosphere from bottom.

I've tried every setting possible and still the same result. It's probable 3mm thick or so. I used to weld alot of car exhaust systems (1mm wall thick pipe)before and that worked out fine.

I've seen the "volcano" at the end of the weld before at work. It turned out to be a bad nozzle seal. It was sucking air past the diffuser and mixing with the shield gas.
Jeff

Yes that is a possible explanation. Will definitely check that out..

Thanks everyone!

[Broccoli1]

Mi_r16-

Is this a new roll of wire?

Looking at the Pic again we something similar on a MM210-

Pull out the wire and blow out the liner- even if it's not the problem it can't hurt

Try another roll of wire if you have one around .

Ed

[Fat-Fab.com]

Are you getting gas flow at the nozzle?
Is the defuser clean and unobstructed?
Is the gas nozzle clean?

I am thinking some kind of gas problem as you might have guessed.

As this is a new issue, then something new has changed look for the NEW difference.

A leak in the gas system can sometimes actually suck in atmosphere, and contaminate the weld.

The volcanoes are indicative of poor gas coverage.

TJ

[fabricator]

as he stated he is using pure co2.although i never tried it,does anyone know if this is even doable?

[Broccoli1]

as he stated he is using pure co2.although i never tried it,does anyone know if this is even doable?

???

CO2 sure, no problem

[Moore]

Maybe.....

Well.. At my school when my mig welds turned out like that.... it was the shielding gas.. there was not enough coverage and/or i had to much stick out and the gas wasn't protecting the molten pool enough thus resulting in bad welds.....
This may be incorrect as I'm not a certified weldor or anything... Although i do plan on it one day...

[tazweld]

Sheild gas

This is only an observation but you can't use straight Argon on carban steel you have to use Argon/CO2 mix. You can however just use the straight Argon on stainless CO2 won't work for you.

[2much2do]

I've used straight CO2 on carbon steel with ok results. It runs kinda hot, so it gave me some problems with burning through the barrel on my smoker. It's ok but I'd tahe the 75/25 blend anyday!!!