What am I doing wrong?

[Damaged]

Hi all, wonder if you can help...

When I'm welding something odd seems to happen.

I'm only welding 1" or 2 " box section or angle but now and again the wire seems to burn back and instead of the usual crackle I'm used to the noise stops and I get a process that seems more like gas welding, when this happens the weld looks a bit odd, where I've had the crackling noise the weld has contour lines but when it goes silent the weld is as smooth as a baby's bum...

Can anybody tell me what is going on?


Many thanks, Mick.

 

[Paul.]

Mick
It sounds as if the wire is not feeding properly, maybe a torch / liner service is due, or could just be the contact tip needs replacing, is the reel free to move ok.

 

[Damaged]

Thanks Paul,

Torch and liner are brand new (Binzel MB25)

I've set the wire feed tension but haven't touched the braking tension on the reel, could this be the problem?

 

[Paul.]

Thanks Paul,



I've set the wire feed tension but haven't touched the braking tension on the reel, could this be the problem?

Could be, also try and keep the lead straight when welding. sometimes you can get a badly wound reel that will cause problems.

 

[Damaged]

Thanks,

I'm using a 5 Kg reel at the moment and the alignment dosen't look good, maybe things will be better when I put on a proper sized reel.

 

[runnach]

Even with a proper size reel you can get a rogue one, had this yesterday, welding well, then bag o nails, wanting to burn back, went through the usual motions to no avail, spool (15kg) was pretty close to requiring a change, removed, new one in, went like a dream, so the rogue spool can be problematic anywhere along its usage, no way to tell until it happens.........unfortunately.

 

[jugs]

I used to have this problem, but penicilin soon fix... no no wrong forum it was the nut lose on the coil center bolt being tightened as the coil went round put Nylok nut on all ok. Wire should come stright off coil into wire feed not at an angle. good luck
Check your nuts

 

[moltonsteel]

Hi all, wonder if you can help...

When I'm welding something odd seems to happen.

I'm only welding 1" or 2 " box section or angle but now and again the wire seems to burn back and instead of the usual crackle I'm used to the noise stops and I get a process that seems more like gas welding, when this happens the weld looks a bit odd, where I've had the crackling noise the weld has contour lines but when it goes silent the weld is as smooth as a baby's bum...

Can anybody tell me what is going on?


Many thanks, Mick.

try cleaning the dirt/dust out of the wire guides found before and after the wire tentioners(rollers).also its best to have the cable straight not looped and i know it sounds dumb but make sure your not steping on the cable the wire feeds threw

 

[moltonsteel]

try cleaning the dirt/dust out of the wire guides found before and after the wire tentioners(rollers).also its best to have the cable straight not looped and i know it sounds dumb but make sure your not steping on the cable the wire feeds threw