Problems with 0.6 wire.

[Rbertnitro]

Hi ive been having some issues with my new Sealey Mightymig 150. Been practicing loads on 0.9mm sheet with some lincoln innersheild flux core and its been going great im feeling confident at producing decent welds in thin stuff with no blowholes.
However im having a real hard time now im trying 0.6 solid wire with 85% argon disposable bottle mix.
On my 2 lowest power settings it seems im just 'pop pop popping' on top of the metal without making any sort of usefull penetration this is the same when i tweak the feed speed up or down the molten metal just dances and balls on the top of the work.on the 2 higher settings its more stable but doesnt have the nice 'bacon sizzle' sound instead just a constant high pitched buzz like a transformer running and to achieve this i need to set the power pretty high and pump the speed up to around 7 or itl pop like mad.

Can anyone please advise me on what ive done wrong? so far ive double checked the polarity,checked for gas flow and turned it up max,and wire seems to feed out smoothly,checked using correct roller, only thing i can think of is i still have the tip in for the thicker wire but i didnt think this would cause these problems

Any help would be greatly appreciated.

Rob

 

[Fixer]

did you reverse the connections of torch and lead? you have it other way for gas.


edit - sorry just seen you checked that, my bad

 

[the snooper]

the wrong size tip can cause problems as its the tip that transfers the power to the wire

 

[Steve Gray]

IThink the wrong contact tip could make a difference mate, what size was wire was you using before??

Ive never actually used the incorrect tip so I have no experience of the effects, but I would suspect it may cause reduced or intermittent transfer of current from the tip to the wire. I would try the correct tip, im sure someone who knows alot more than me (its not hard lol) will be along to help with your problem more comprehensively!

 

[Steve Gray]

Snooper and Fixer replied as I was typing lol

 

[Fixer]

i will say this - I NEVER got anywhere with disposables. I think the mini regulators are dodgy too.

 

[Rbertnitro]

thanks for your input guys. i was using 0.9 innersheild thru a 1.0mm tip i think. now that i think about it 0.6 wire is gonna be really loose in there isnt it.
Unsure on pressure as disposable reg but i could hear a lot coming out.im planning on visiting a hobbyweld dealer just down the road soon anyway.
Is there anything else worth checking with this?

I forgot to note when id had enough of the 0.6 wire when changing spools as i released the roller and was winding the free wire back onto the spool it wounldnt wind back and pull back up thru the torch at first it was stuck tight it would go forward but not back.only when i switched back on and squirted a few cms of wire back out the torch did it free off and able to wind back thru.Could i have a wire/roller/liner issue?

 

[the snooper]

you cant adjust pressure on disposable regs they are on / off pre set regulators

 

[Fixer]

thanks for your input guys. i was using 0.9 innersheild thru a 1.0mm tip i think. now that i think about it 0.6 wire is gonna be really loose in there isnt it.
Unsure on pressure as disposable reg but i could hear a lot coming out.im planning on visiting a hobbyweld dealer just down the road soon anyway.
Is there anything else worth checking with this?

I forgot to note when id had enough of the 0.6 wire when changing spools as i released the roller and was winding the free wire back onto the spool it wounldnt wind back and pull back up thru the torch at first it was stuck tight it would go forward but not back.only when i switched back on and squirted a few cms of wire back out the torch did it free off and able to wind back thru.Could i have a wire/roller/liner issue?

Sound like it. Is the liner a coiled steel type or plastic? Ive been using 0.8 tips for 0.6 wire forever… its widely recommended so i doubt thats the problem. I use to get the wire sticking in the tip when i used the correct sizes.

 

[Rbertnitro]

Sound like it. Is the liner a coiled steel type or plastic? Ive been using 0.8 tips for 0.6 wire forever… its widely recommended so i doubt thats the problem. I use to get the wire sticking in the tip when i used the correct sizes.

Unsure what liner im running in this (Sealey mighty 150) although id suspect plastic as it seems like a basic entry welder and the guide tube at the rollers is plastic.
Had no jamming or feed issues with the 0.9 flux core though.

 

[Fixer]

Steel liner probably worth a punt then.

 

[Rbertnitro]

Steel liner probably worth a punt then.

Thanks seems like a decent mod in general if its gona feed better and last longer. Are they readily available for my welder and are they straightforward to fit?

 

[Fixer]

You'l find them on ebay… if your unsure, contact the seller with your make and model of welder. Ive never fitted one since my machine came with one but I doubt its hard to pull it out and thread a new one in - others who have done it may have tips...

 

[Jan]

Can't speak for your machine, but I replaced the plastic (?PTFE?) liner on my SIP MigMate 130 with a steel wire liner as a simple 'one out, one in' job in a few minutes.

 

[Robotstar5]

You can even use net curtain wire!

 

[Jan]

With the correct liner only costing around the £4 mark why bother with a slightly cheaper substitute?

 

[Geodawg]

Rob,
can I ask you what settings you used while using the 0.9. I've got the same machine as you and I've just started paying with it, but I keep blowing holes in thin metal if I try to weld two bit together. Seem to be able to get a decent run down a single sheet but as soon as I try to join anything I'm goosed.

Cheers,

Geo

 

[PSweeney]

should already have a steel liner but ensure you are getting a smooth feed. Also clip the ball from the wire each time and for lower amps have the tip closer to the work piece.