Best flux-core settings for Hitbox HBM1200 on 20×20×2.5 mm box section

[Mjg6468]

Hi all,

I’m using a Hitbox HBM1200 3-in-1 welder in gasless MIG (flux-core) mode and trying to dial in the best settings for 20×20×2.5 mm mild steel box section.

Machine setup:

• 0.8 mm E71T-GS flux-core wire
• Torch is hard-wired (negative internally)
• Earth clamp connected to the + socket for DCEN polarity
• Standard 230 V supply
• 
  
• I have attached a few pics of the HBM1200 itself so you can see the setup.

Just after some advice from anyone who’s run the same or similar Hitbox:

• What power and wire-feed settings work best for 2–3 mm box?
• Any tips on travel speed or technique to avoid burn-through?
• Do you find short bursts or continuous runs work better on thin box?

Appreciate any help — just trying to get a nice smooth arc and decent penetration before I start tacking up a frame.

Cheers,

 

[BrokenBiker]

What is the maximum output of the welder? Is it like mine where the 'wire feed' dial alters a displayed amp figure? Or is it like a conventional mig with normal voltage and feed adjustments?

My hitbox is different to yours but the easiest way to figure out settings is just just try on scrap, set both dials to 12o'clock...try and run a bead....if it's sputtering and spattering, turn the wire up til you get a nice bead profile, if it then still seems cold turn the voltage up, run a bead...if it seems too hot, turn voltage down and if it feels like the wire is trying to push the torch away turn the wire down...rinse and repeat til you get the weld you want.

As for travel speed, you want to watch the puddle and maintain a consistent arc length and weld bead width...travel speed is effected by setting, technique, joint type etc...i personally run hot and fast, others run colder but slower...same outcome...

If your settings and technique are good, you can do thin wall box section in 1 run...I weld 2-3mm thickness for virtually everything I make and do 50x50 box in 1 pass per side with gasless, solid wire, tig or stick.

One thing to consider, is that mig starts cold, and in short runs like 25mm box, you may want to light up in the middle then 'hop' back to the start so the start of the joint is nicely hot. I do this with mig and stick as you can't really hang about like tig to get the start hot.