MIG Wire variability?

[ChrisXenon]

Hi folks,

We are beginners. We bought a Sealey Mighty MIG 150 amp machine a few weeks ago. We got a .9KG of flux wire with the package of things we bought, and we've been turning it into junk - as you do. It ran out today.

So we fitted the other reel - this time .45KG of flux wire - which came in the box with the welder.

Chalk and cheese! The fizzle was louder and more constant, The whole weld process was far brighter - we could see! The weld was so much hotter that we had to turn it down to avoid blowing holes. The weld was far far better, and there was almost no slag, with silver metal being visible instead of the tan dusty coating we've been used to.

Both wires came in boxes which said it was the same stuff - Sealey's own flux core wire. 0.9mm. ET71 something I think (I'm not with the welder now).

So my question is - is it usual to find huge variability in flux core wire like this? If it is, what's the safest bet for the best weld? If not, might there be another reason for us seeing this huge difference?

In each case, it was feeding fine, the work was well contacted by the clamp, and the welder setting were initially the same.

Thanks guys,
Chris

 

[rtbcomp]

Welcome to the forum.

This is a common issue, I suspect the chepaer brands source wire from anywhere and stick their own name on it.

Stick with good brand names, I'm sure people will be along soon to recommend their favourites!

 

[BrokenBiker]

i use sip gasless wire found in Halfords. Been through more reels than i care to count and never had a bad one. Tried some cheaper wires from motor factors and ebay but always came back to sip, never finished a roll of cheap stuff as its usually that bad i give up

 

[ChrisXenon]

Thanks guys.

I'm surprised that Sealey would re-badge wire on one spool, and not do it on another, but perhaps they do, and it seems the most logical answer.
I'll write to them and ask - hahahaha - I'm sure they'll confirm that they've b@stards

We'll get the Halford's stuff in future.

 

[Country Joe]

So my question is - is it usual to find huge variability in flux core wire like this? If it is, what's the safest bet for the best weld?

The point rtbcomp is making, is that when a company re-brands any old shonk, from an unknown source, it will have a tendency to vary from reel to reel, even if you bought them at the same time.

If you're after any amount of consistency, you could try Lincoln NR 211 MP.
The Halfords stuff will work, but not nearly as well as the Lincoln, I found.

A cylinder of shielding gas would be yet another improvement, again!

All the Best,
CJ