Gasless

[GKQ]

Well I know people dont like gasless but I have a question.
I'm using BOC smoothcore 11 gasless mig wire ( for galvanised steel hence gasless ), the correct size tip 0.9mm, and correct polarity DC-.

Why does the tip clog ? Seems to work realy well for 1m or so of weld then starts to splutter as the wire feed struggles to come through. If I change the tip all works well again for another 1m.
I have tried:
1) anti splatter on the tip (BOC staff suggested this )
2) Using larger tip, makes no difference.
3) increased / decreased roller tension, no change.
4) Changing wire feed speed BOC recommend 4-5.7m/min

Any other suggestions ?

regards

Graham

 

[Omniata]

Sounds like it's burning back into the tip, a higher wire feed speed should rectify it, and or a slight increase in tension on the rollers...

Have you checked the liner? Could be clogged?
Is the wire rusty, or the rollers worn?

I used to have issues that were partly overcome by getting some little "clip on wrap around" pads that were slightly abrasive, they came in pairs, red and black, you applied lube to one, black, and left the other dry to clean, red, red first, black second before the feed rollers...
Made by Weld-Aid...

Edit: Is the wire 0.8mm or 0.9mm, IIRC you need a 0.9mm tip for 0.8mm wire...
Edit2: Is there a tensioner on the wire reel?, is it getting caught or tightening up as the wire feeds, try running 1m of wire through without welding and see if it starts to slow down or not...

 

[Omniata]

Tech sheet attached...
What settings are you running on?

I clicked on the wrong wire available to you previously, if it's 0.9mm wire, you may need a 1.0mm tip.
It's designed for automated welding, are you doing it freehand?

 

[GKQ]

Right, Thanks for all the tips I have tried / replaced

New liner when I put wire in, so hopefully not that.
Feeds very smoothly until welding for 1m or so, might be getting to hot ?
Will try 1mm tip and see how it goes have been using 0.9mm.

Using Esab mig caddy 200 , no tensioner on wire real.

Got the tech sheet, thanks anyway.

BOC said it would be OK for free hand, so might go back and see what they say.
Otherwise why would free hand be that much different from semi auto / full auto ?

Graham

 

[Omniata]

You say it stalls after running 1m of wire. How long is the weld for 1m of wire?

I'm wondering if you could try running multiple short 500mm welds with a brief 30 second pause in between, and see if it still sticks?

 

[GKQ]

It seems it's me. The liner is indeed new but just checked packaging ( yes I know should throw it all away, but ....) and it is for 0.6-0.8 mm wire not 0.9mm so will have to change the liner to a larger size.
Thanks for all the suggestions needed a kick in the a*** to make me check.

Regards
Graham

 

[gordon stephenson]

You might benifit from recessing the tip inside the nozzle a little, The zinc in the galv will be boiling off and may be contaminating the tip causing the clogging,

 

[Omniata]

Let us know how you get on