wire sticking

  1. hoppo Member

    Messages:
    8
    hi my names paul new to the welding game just bought a cosmo gas/gasless 170. started practicing going well untill wire started sticking in end of gun had to pull wire out with pliers but kept on sticking is please help:confused: :confused:
     
  2. malcolm

    malcolm Hej!

    Messages:
    8,871
    Location:
    Bedford UK
    Welcome to the forum hoppo,

    There are a few reasons why the wire might stick. The most likely is the copper tip at the end of the gun has gone a bit out of shape or has a bit of weld in it and needs replacing (they don't last long). The tips are very cheap so it's worth getting a few of them.

    The other possibilities are to do with the wire feed - if the tensioner is a bit slack or if the welding wire has become a bit rusty and the wire rollers aren't gripping then the wire might stop and stick with the slight extra resistance when the end of the wire hits the metal or when the tip gets hot.
     
  3. Hitch

    Hitch Moderator Staff Member

    Messages:
    11,998
    Somerset
    Another tip, especially for that type of machine is to keep the torch (cable) as straight as you can.
     
  4. hoppo Member

    Messages:
    8
    forgot to say this welder is new 1 day old new wire new tip ??
     
  5. malcolm

    malcolm Hej!

    Messages:
    8,871
    Location:
    Bedford UK
    If you've checked the tip for damage, and checked the wire feed tensioner, then possibly it's technique.

    Are you getting a blob of weld forming on the end of the wire which travels back to the tip and sticks? In that case probably the wire speed is set too low.
     
  6. hoppo Member

    Messages:
    8
    each time it sticks there is at least quarter of a inch sticking out from the shroud
     
  7. malcolm

    malcolm Hej!

    Messages:
    8,871
    Location:
    Bedford UK
    That does sound very odd.

    One thing to check - is the tip the right size for the wire? That sort of thing might happen with 0.8mm wire being run through a tip designed for 0.6mm wire. Works until it gets a little hot.

    Otherwise - trying to think of a safe way to do this.... if you grip the wire between your fingers and pull the trigger (holding the torch miles away from anything it could arc against) is it really easy to stop the wire coming out? That would indicate wire feed problems.

    Does seem odd that the wire isn't burning back to the tip after it sticks. Can't think of any reason why it wouldn't vaporise after it sticks.
     
  8. malcolm

    malcolm Hej!

    Messages:
    8,871
    Location:
    Bedford UK
    Thought of something else - is the tip shorting against the shroud? Maybe there are some bits of metal in there. If so then the wire would short against the tip whenever the shroud touched the metal you are trying to weld. That would explain why the wire isn't being burned back - the electricity wouldn't be going through that bit of wire.
     
  9. Hitch

    Hitch Moderator Staff Member

    Messages:
    11,998
    Somerset
    Does you machine have a spot weld timer....?
    Make sure its turned off if you do!
     
  10. neil Member

    Messages:
    27
    humberside uk
    ive found that if you use a o.8 tip with 0.6 wire then it very rarely sticks,
    also when i bought my welder new i didnt check the feed roller, it was set for gasless wire and i put 0.6 in wich led to the wire constantly sticking with a
    bit of wire protruding from the end of the torch so it was,nt sticking in the
    tip, it just was,nt being fed through properly. as yours is a new machine, you
    could have the same problem, cheers, neil..
     
  11. hoppo Member

    Messages:
    8
    changed tip & wire keeping torch cable as straight as poss everything seems to be ok now so thanks alot for your advise cheers paul
     
  12. clunk Member

    Messages:
    9
    Co. Meath, Ireland
    I've recently purchased the Cosmo 130 dp machine.

    i also find the wire feed isn't the best.

    The thing I dont understand is that everything I read prior to buying one says the wire should come off the top of the spool.

    Cosmo's have a sticker inside saying take it off the bottom.
    This leads to quite a steep angle for the wire to pass into the feed rollers.

    any idea why i shouldn't turn the spool over?

    andy
     
  13. malcolm

    malcolm Hej!

    Messages:
    8,871
    Location:
    Bedford UK
    It does seem very strange to take the wire from the bottom of the reel, especially if it means the wire has to go through a tight turn on it's way to the rollers.

    Try turning the reel over and see what happens.
     
  14. hoppo Member

    Messages:
    8
    turning reel over

    i forgot to say i also turned the reel over so that is comes of the top
     
  15. hoppo Member

    Messages:
    8
    trailer

    i was making a roof rack for a trailer i aquired done that turned out ok. need another project now thinking of making a securty gate for single garage door anybody have any simply plans i could follow please
     
    Last edited: Feb 11, 2006
  16. Hitch

    Hitch Moderator Staff Member

    Messages:
    11,998
    Somerset
    Heres a pair of security gates i will be starting end of the month...
    40x10 flat bar frame, 12diam bars, laser cut letters and notes....
    Have done all the auto cad for it aswell, but im bored of it now! lol

    Dont take my sizes though!!
     
    • wwgatewithdims.JPG
  17. malcolm

    malcolm Hej!

    Messages:
    8,871
    Location:
    Bedford UK
    I like the musical gates. Thank heavens for laser cutting - wouldn't fancy cutting all of those bits out by hand. I'd love to see a photo of them when they are finished.

    I couldn't find any plans on the interweb for simple gates (my search returned a few gate makers and a dentist!) Might be best to measure up and draw something on paper, work out the lengths, then knock something up.
     
  18. hoppo Member

    Messages:
    8
    musical gates

    bit too fancy for garage but thanks anyway think i will work it out as i go along
     
  19. Hitch

    Hitch Moderator Staff Member

    Messages:
    11,998
    Somerset
    Theres a few here you could adapt http://www.lancesecuritydoors.com.au/security/screens/colonial_castings_door_screens_n_grilles.html

    And for inspiration, look at http://www.brindley-steel-forging.co.uk/shop/index.htm


    Its quite lucky, we have a laser cutter at work. I will just get standard notes cut, and the joined ones i will just weld a strip beween them.
    I will get some pics once they are done.
    The bars will be plug welded through the frame, and the notes will also be plug welded on, so virtualy no weld will be visible.
     
  20. hoppo Member

    Messages:
    8
    sorted

    first thanks for links & help . forgot to mention i was useing gasless. just got a gas bottle full from kind landlord (pub) running 0.06 wire through 0.08 tip much easyer to weld better results am well chuft throwing gasless wire away crap.
     
Advertisements