MIG wire diameter between manufacturers

[Munkul]

Ah, I thought cast wasn't so important with a 4 roll feeder. And I always run with minimum tension needed

Anyway I'll fiddle tonight until I've got to the root of the problem. It's no good having a MIG that doesn't weld properly.

 

[TechnicAl]

Ah, I thought cast wasn't so important with a 4 roll feeder. And I always run with minimum tension needed

Anyway I'll fiddle tonight until I've got to the root of the problem. It's no good having a MIG that doesn't weld properly.

It makes a difference and its important at the extremes.....way too small or way too big...

 

[backpurge]

Ah, I thought cast wasn't so important with a 4 roll feeder. And I always run with minimum tension needed

Anyway I'll fiddle tonight until I've got to the root of the problem. It's no good having a MIG that doesn't weld properly.

Another simple check is to remove a few metres off of the reel and just run the contact tip down it, obviously it should slide down the wire smoothly with minimal and consistent resistance

 

[TechnicAl]

Another simple check is to remove a few metres off of the reel and just run the contact tip down it, obviously it should slide down the wire smoothly with minimal and consistent resistance

True.......some of the tips are woeful....Tweco have a good reputation but ive seen some where the hole was almost exiting from one side.....I always preferred the sorter ones....whats the point of those about 1.5 inches long....you only need to touch to make contact.

 

[Munkul]

Another simple check is to remove a few metres off of the reel and just run the contact tip down it, obviously it should slide down the wire smoothly with minimal and consistent resistance

That was one of the first things I checked. The tips run smoothly down both wires, but definitely looser on the Bohler wire.

 

[Munkul]

OK so I didn't get down to the workshop til late, but I did have a play around.

Cast of both wire seems fine.

1. Checked reel tension, guide wear, roller tension, liner, gun, tip etc. All ok. Wire basket as described, is dodgy, it doesn't turn on the hub smoothly and had a few areas where the wire layers had moved.

2. set up welder on some scrap metal around 220 amps, welded like ***, could still feel a slight drag on the wire sometimes (but not always). Poor starts, turbulent puddle, spatter, voltage didn't seem to make much difference.

3. Loaded new reel of Bohler wire, welded at same settings, welded nicely. Good starts, good puddle, little spatter.

4. set welder to around 150 amps, welded nicely.

5. changed back to esab wire, welded nicely.

6. set back up to 220ish amps, welded like *** again.

Now it makes sense if the wire is hanging up over higher WFS, but not sure why it makes a difference to arc starts...
I still think the Esab wire is just ever so slightly too big for my tips.
It could just be struggling to pull it off the reel now and again, it shouldn't be, but that's all I can figure out.
So I think I'll scrap that Esab reel and chalk it up to basket damage, learn to check the baskets next time.

BTW the Bohler wire has a China label on it and it wasn't perfectly round when mic'ed. Definitely not as good quality as Esab. But it runs fine, and tbf that's more important than COO.