Gasless Welding.

[Mikes1670]

I have a virtually brand new Clarke MIG 130EN Gas/No GAS welder so everything in good order. I set the welder up for gasless welding and used the flux cored wired supplied with the welder. I have to say though the results were awful - the welds produced were full of holes (porosity I think its called) - I have since moved on to sheilded first CO2 then Argon/C02 which gave instantaneously superior results (after changing the polarity etc). But it comes at a cost (disposable bottles - £££'s). So, I feel I may need to re-visit the flux cored set-up - Any advice, tips on how to get this to work yet still give good quality welds aesthetically and structurally??


PS I would also add that the welder seems a lot more powerful when using Argon/Co2 sheilding gas, 0.8 wire works best for me and seems to give better penetration.

 

[keith19]

First read up all you can find on gasless welding; the more you know, the quicker you can realise what may be going wrong. Watch the tutorials on here and on youtube, and anywhere else. Watch the Miller videos too, although the kit is far superior to what we are working with.

I have a Clarke 151EN and have done gasless welding only for the last 18 months or so. I found it easier to get into than I thought it would be, but maybe this is because I used to do a bit of stick welding.
The two processes are somewhat alike; you pull rather than push most of the time. It is important to use an auto mask so you can keep both hands guiding the torch, and you do have to crank your head over a bit more just to see what's going on. Keep out of the smoky fumes if you can, I like to weld outside or somewhere close to an open door.

The quality of the flux-cored wire is most important in gas welding - bad wire can make you think you are doing it all wrong, and make for a confusing experience. I generally use flux-core for slightly heavier stuff outdoors, fence and gate repairs, brackets, etc. Thicknesses of about 2mm upwards seem better for gasless welding, but I have also done van bodywork down to about 0.9mm, using both 0.9 and 0.8mm flux-cored wire. Some on here, more experienced, can use it down to 0.8 or 0.7mm bodywork.

It is very important to use the Thin Metal Technique (TMT) when using flux-core on thin sheet; almost essential if you are to avoid blow-through.

Personally I like Lincoln Innershield flux-cored wire the best. It costs a bit more, and it demands clean metal, but it is a treat to use compared with some of the cheaper brands. Amongst the cheaper stuff I used a roll of Sealey which was not bad, either.

So as for gas wire welding, start on something around 3mm thick, and gradually work your way down from there, over a period of time. The welds will never look as good as gas-wire welds, but for a good strong job with maximum convenience flux-core is very useful.

 

[cracker666]

I was going the route you have gone.
I was happy with the weld but the time taken to clean up was well not worth it.
One tip I was told of masking take either side of the joint then antisplatter spray it.
When finished welding unpeal and less mess to grind back.

I decided to go the argon route I bought a decent reg from the bay, an adapter pipe also from the bay and some Adams gas.
If your welding a lot then the vziboc bottles the way to go.
+1 for the Lincoln wire and I also got some big bags of silica gel to stop it getting damp.

I now will not go back to gassless as its too bloody messy and not worth it.
Maybe on a farm or field where gas isn't a good idea, but the arc is less powerfully on gas and more controllable.

 

[Wookster]

I started with gasless and used it for years for structural bodywork etc without problems.
Would still do today if it's windy and outdoors.
Too messy for bodywork though, best option is to go with BOC Volkzone offer.
Cost is about £35 a year rental and £25 a refill for a 40kg bottle.
Regulator will cost about £30.
If you decide after a few months you don't need it anymore you get a proportion of the rental back but lose the gas.

 

[schnappi]

FWIW, I've always managed fine with gasless doing all sorts. It's messier and seeing what's going on is a bit harder but I think it gets an undeserved bad press. Sure it's not as nice to weld with compared to ordinary wire and gas but in many ways it's a lot more convenient, especially when welding outdoors or mobile welding.

I've done bodywork with it without much trouble using a stitch technique. Just need to move a bit quicker and develop a feel for it.

 

[shenion]

I tried my 130EN with the gasless wire that came with it and was not impressed.

I think better wire will help. I have used the Lincoln gasless and it was not bad.