Tip size / wire size (new bee question)

[Geodawg]

Hi guys,
been sitting on the side lines and read a lot of stuff that is pointing me in the right direction. But there's one question I hope you can put me right on. I have a SEALEY MIGHTYMIG 150 Professional Gas/No-Gas machine which I got a while back for a very good price, with the intention of learning enough to allow me to patch my van (ongoing project).
The machine came with a 0.6 tip and a 0.9 tip and 0.9 flux core wire. I've been playing with the 0.9 and not too impressed with my results so far (not put off) but was wondering if I can use 0.8 flux core with the 0.9 tip? I'm also thinking of converting to gas and going down the 'BOC Volkszone deal' route. In your opinion would I be better getting the same size tips as wire. and since the majority of the stuff I plan to do will be patches for the van (thin metal), should I go for a 0.6 or 0.8 tip and wire?

thanks for any advice you can offer.

Geo

 

[MoreWellie]

for thin metal you would be better off with 0.6 and definitely match the tip size to the wire. Tips wear and the hole size increases which causes issues and is why the tips are easily replaceable items

I am sure very experienced welders can weld thin metal with thicker wire but for mortals the thin wire will make it easier

I haven't tried flux wire but everything I have read suggests the different makes are variable in quality and that welding with gas is easier and more consistent so I have stuck with gas

 

[Geodawg]

Thanks for the quick reply mate. 0.6 it is then

cheers,

Geo

 

[MoreWellie]

just in case you are not already aware. The 0.6 wire is only useable with gas so you will either need the volkszone offer or look at rental free gas whichever is more convenient for you

the 0.6 will also require a smaller slot on the drive roller in your welder. The rollers often have dual slots so you may be able to turn it round or you may need a new drive roller

 

[BrokenBiker]

I have used 0.8 gasless wire to weld cars. cant run a continuos bead and stitch welding is a bit tricky due to the slag freezing on the puddle, but if you evenly space your tack, clean them off then overlap the next set of tacks etc it works fine

 

[Geodawg]

MoreWellie thanks for that, I'm looking to use gas, from what I've read on here, seems to point to that being the best option for a new-b like me to get a decent weld with practice... Funny enough I just posted on another thread asking if anyone had a contact in the Glasgow area Re BOC Volkzone offer...

brokenbiker, that's also good to know, thanks for that snippet.

 

[Geodawg]

guys, don't know if I should start a new thread or if it's ok to keep this one going with another couple of questions. I got some 0.6 wire and changed over to gas (bought a disposable while in halfords argon co2 mix) Firstly I was amazed at the difference right away, didn't blow through the test bits I was previously using and blowing through with the 0.9 gasless wire, and the cleanness. but the down side is, I seem to have a leak in the torch from the wee silver square bit in the pic.

If I press it, the leaks stops. or if I reduce the amount of gas. I've done a quick Google and don't seem to be able to find this as a spare part I'll drop Sealey an email see if the do a spare. If they don't, do you have any advice on a replacement torch?

also do these test welds look a bit high? they were done on the lowest power setting for my machine, and the gas was around 5lm (according to my peashooter gauge, and couldn't get the pressure up due to the leak)

this is the back of the welds (is the penetration pants?)

thanks for any help you can offer.

 

[MoreWellie]

I would up the power and/or wire speed a bit and try again. assuming this is 1mm I would expect a bit more penetration and a lower weld height. welding on the middle of a panel needs a bit more grunt/different technique than welding to the edge of it

on this sort of power setting I believe 5lpm would be ok, the disposable bottle regulators don't allow much more than that and if you look at the number of litres in the bottle you will see that you won't get much welding time at that setting anyway

no idea on the torch except I might try using a tie wrap to hold something pressing on the plate if that stops the gas leak, obviously not the "correct" solution

 

[Geodawg]

Cheers MoreWellie, You're correct in your assumption mate, it's about 1mm thick (some spare cabinet blanks I had kicking around to play with) I'll have another wee go tonight (if there's any gas left lol) with the power up to the next level and up the speed as you suggest.. the only reason I'm using the disposable is I couldn't wait to play with gas. I've signed up for the volkszone deal just waiting on the paperwork coming through, then I can play till my hearts content (or the missus drags me out the garage) I've managed to source a replacement torch on the bay of flees so hopefully I'll be sorted on that front. One last question if you dont mind, when I get my bottle and propper reg what lpm should I be looking at? Thanks again for taking the time to answer and you help mate.

Geo

 

[Jan]

In most circumstances a flow rate of 10L/min should be more than adequate. If working in draughty conditions you may need to up that, but it's best to shield your work area as too much gas flow can actually be counter productive. If all else fails you may consider reversing the polarity and using gasless/flux cored wire.
As for the leak; a smear of silicone sealant under that plate should have done the job if left long enough to set as there's sod all pressure inside the torch head.

 

[Geodawg]

Cheers Jan, I'll pop some silicon under the plate and keep it as a spare