Change of gasless MIG wire

[benson12]

Hi all,
Im new to the site and have just replaced the gasless MIG wire, however the new stuff isnt producing a weld bead and just spattering all over the work piece. My old wire was 1/2Kg small roll only markings I can see are MP526. The new spool is a 4.5Kg and E71T-GS.
Would the heavier spool cause this problem? and if what am i doing wrong. Ive noticed the welder seems to be tripping out too.

 

[TechnicAl]

E17T-GS suggests Gas Shielded to me. I dont know it so Im not sure

Usually its E71T-1 which is the spec for gas shielded mild steel

 

[benson12]

Thanks TechnicAl,

Ive just gone to garage to check box, its E71T-GS, not E17T-GS as i wrote, but it does say gasless flux cored wire

 

[Lawnmowerboy]

wrong tip? ***** wire?

 

[benson12]

im using 0.8mm tip (same as old wire), yet i cannot tune the welder in to achieve any sort of bead at all, just spatter all over work.
I cant understand it, its the same diameter wire, but only it seems to produce more smoke/fumes when burning.

 

[Lawnmowerboy]

hmm try it with all wire feed settings

 

[shenion]

What brand wire; Chinese junk?

 

[benson12]

super 6 wire (american i think)

 

[benson12]

it only has 4 settings 1 min, 2 min 1 max and 2 max and i have cycled through wire speed from 1-10 and it all looks the same.
i thought i was doing so well too. My welding was improving loads but now i feel im back to square one!!!!!

 

[shenion]

Is the polarity right?

Some brands don't work well reversed, others do.

 

[keith19]

Could be GS means something like 'General Specification' or all-purpose flux-core?

Sometimes on a small hobby welder with a puny motor a 4.5Kg reel will slow down the wire feed off the reel a bit, because the motor is having trouble turning the reel. But more usual using a 15Kg reel with adaptors, than with 5kg.
If this is a Giant you're using it would be unlikely to be that, though?

Is this new wire the same thickness? Most flux core is 0.8 or 0.9 mm, or 1.0mm. If it is a different size the wire feed rollers may need to be adjusted. Rollers that were set to pull through 1.0 mm may slip on 0.8 mm unless reset, for example.

As already said, check the tip size too. What make wire are you now using? Some brands of wire are known to work much better than others. Easiest way to check the wire is buy a small reel of known good brand and try that, leaving the settings as before with your first reel of wire.

 

[benson12]

yes, ive simply exchanged one gasless wire with another albeit a larger hevier spool. i cant understand it at all

 

[benson12]

Hi Keith,

Yes it is the same thickness being 0.8mm as is the contact tip. i auusumed that the wire that came with the welder would be of a poorer quality however i could maintain a very good bead and specifically asked the supplier for a good quality wire thinking my bead would be that much better.
it only produces spatter on the work piece though

 

[keith19]

Does the wire itself seem to feed easily through the torch, when you hold it up to watch, or does it appear to be catching or feeding erratically? If so, it might be misshapen wire being dragged through the rollers, catching and slipping.

If it does drag or slip, try gently pulling the wire through the torch by hand, with your finger on the trigger, and with the roller feed clamp off so the wire pulls easily, and with the power on and the earth clamp well out of the way. Does it feel as if it is still 'snagging' somewhere inside the torch cable? If it's smooth now, the problem is either the wire or the setting of the rollers. If it is still catching, it could be the wire catching the tip, so change the tip, or the wire catching somewhere inside the liner, or at either end connection, in the torch or inside the machine where the cable is located.

If there is no problem with the wire feed at all, and you are on the same machine settings as your original reel of wire, it is looking like there may be a problem with the wire itself.

Just to test again, have you tried just laying a bead on some 3 mm steel or thicker, with the settings in the middle of the range, and wire speed in the middle of its range, just to see if it can lay a bead at all? Try this on several settings.

If it is not the new wire, the most likely culprit, it is possible that co-incidentally the machine has developed a fault inside, but this is less likely.

One other basic thing not discussed, is have you changed the earth clamp, or moved the earth clamp to somewhere it is getting a poor connection? Is it clamped to clean steel, not just anywhere on the bench?

 

[benson12]

it does seem a bit irratic in that it will stop feeding the wire, then the welder is tripping out. I will change the contact tip and your other recommendations in the morning. I have tried all wire feed settings and it all looks the same, spatter everywhere and no weld bead at all. Its very frustrating.
I am beginning to thing it may be an issue with the rollers as the wire is definately the right specification for gasless welding.
Thanks for the advice, I'll let you know how i get on

 

[grandads_shed]

you never came back on this ,
did you find the problem m8 ???

 

[aametalmaster]

Also check the nut tension on the spool spindle. You said you went to a heavier spool of wire maybe the extra weight is causing more drag...Bob

 

[migman2014]

If the only change made is the weight of wire maybe its making the welder drag.try tightening the wire feed slightly if you can or resort back to a spool like you were using.this will prove if it is the weight doing it or a coincidence that your welder is acting up. Hope this helps.

 

[Wozzaaah]

18 month old thread chaps, the OP hasn't bothered to come back since asking for help.