Time for watercooled torch?

[morph]

I struggling at the moment keeping my torch in contact tips. Got a big (60m x 40m) shed to weld up and once I get the welder into a good spray transfer the tips just burn out. Did 4 in under 5 minutes today so dropped down to dip and they last for hours. So is the problem my settings...

Spray 310 amps 31volts
Dip 270amp 27volts

I'm using 1mm wire and a genuine MB36 with M8 tips but I cant keep it in spray

What sort of settings do you guys run on heavy work?? Do your tips last ok?

Or should i go watercooled as i only need the torch? Got free water (borehole) so i'd just connect to a tap and run it down the drain...

Thanks in advanced

 

[volition82]

I don't think fiitting a water cooled torch will cure the problem. IMO your settings are way to high, I have used a lot of 1.2mm wire and the maximum setting i've used is 280-300 amps. That was including joining 20mm plate to 100mm plate and having to pre-heat the material.

A company I worked for did get a water cooled welder for one job which was welding 5 metre long fillets on plate(25mm to 30mm) joined in a t-section. The t-sections were joined back to back and welded in one go, staggering the welds. We started welding them with a normal welder/torch and it worked well but the water cooled version made it more comfortable for the person welding, made the torch last longer and it welded slightly better. I would get through a reel of wire a day when welding on that job.

 

[morph]

I Completely agree about the settings but im just a bit confused as to why im not getting a good spray transfer without running that high?? Been fiddling with the settings a bit but looks like i'll have to try harder. Would 1.2 wire help or make it worse?

 

[volition82]

Are the voltage/amp readings from the machine it's self, if so the machines readings could be out? I've used machines which show amps etc before and they have never tended to be accurate. I just know I used about 280-300 amps from weld tests, the weld inspector would set the welder up which just had numbers (1-4 and 1-10) via a machine which would tell amps etc.

What thickness material are you welding and machine are you using? Personally if I was welding medium to heavy steel structual steel all day I would want 1.2mm, you could do it with 1.0 mm but 1.2mm is a lot quicker which would be good for you as it sounds like you work for yourself? I know it's not as versatile as 1.0mm but i've never really been a fan of it, I think it's a bit heavy for the lighter stuff and not really up to medium/heavy work. You could always have a cheap smaller hobby type welder set up with 0.8mm for the lighter stuff.

 

[morph]

That was the question i should have really asked- " should I bin the 1mm and go to 1.2?" As you say i work for myself, as a farmer so thats why ive been keen to stay as i am- i always have something thin and crappy to weld!!

The readings are off the machine which is 400amp badged as a Hobart but i've seen the same welder in many different guises. I think its Italian and still sold now as mines about 8 years old. I think you could be right about the readings being out as 1 day they will read in the low 200's and the next its up to 300 without changing anything! I hope its not knackered!!

 

[Sparkey]

Wow, yes those settings are high!
With 1,0 mm wire i get into spray at around 200 amps and 24,6 Volts (reading on the machine Oerlikon citowave) and am not burning a lot of tips, approx 1 for an 8 hour shift...lol the only thing that gets burnt are my fingers because of my torch getting hot in spray! (same as yours MB36)
What thickness material are you welding?

 

[morph]

welding 12mil but given whats been said i think there is something very wrong with my welder!! Well the display anyway, i'll try some different settings and ignore the read out as it must be way out. If it displays 200 amp and 24v its gives a very rough dip transfer regardless of wire speed. I suspect its reading about 50 amps high.

 

[Sparkey]

Travelspeed can make a big difference too, have you played with that or (i suspect) you are weaving? Too slow = dip, too fast you drop into globular.....