Need better penetration

[dan1990xj]

As the title says I need better penetration out of my welder, I know a bigger better welder is the best choice but I can't afford one right now, probably not till fall. To start it is a Miller Sidekick MIG and it is only 90amps, it is a 110 unit, and I am running .024 wire (non fluxcore) with 100% CO2. I need to know if I can do anything to get some better penetration out of it. Not sure if it will help to run fluxcore? Fluxcore and CO2? Larger wire (I can run .024, .030, or .035)? Please help me.

[Kartracer55]

You dont need gas with fluxcore... the fluxcore kinda makes its own shielding gas. Im no expert, been learning stick and I was shown Mig real quick last night. By what I understand FCAW makes for a little deeper penetration weld because the puddle is much hotter, however it is alot more fluid than GMAW so you cant really do out of position welding with it


Sit down and browse through this...

http://content.lincolnelectric.com/pdfs/products/literature/c4200.pdf#search='GMAW%20p%20vs%20GMAW%20S'

Its long, so sift through it. Alot of theory on ther different variants of GMAW but they go into some topics of interest.

Jim

[Proeliator]

As the title says I need better penetration

Holmes had it figured out :laughing:

But seriously, just pick up a cheap arc welder if thats what you need. If you were running a mix I'd say straight co2 but your already doing that so...

[Gen. Nonsense]

If possible chamfer the edge(s) of what you are going to weld.

[Static-XJ]

You dont need gas with fluxcore... the fluxcore kinda makes its own shielding gas. Im no expert, been learning stick and I was shown Mig real quick last night. By what I understand FCAW makes for a little deeper penetration weld because the puddle is much hotter, however it is alot more fluid than GMAW so you cant really do out of position welding with it


Sit down and browse through this...

http://content.lincolnelectric.com/pdfs/products/literature/c4200.pdf#search='GMAW%20p%20vs%20GMAW%20S'

Its long, so sift through it. Alot of theory on ther different variants of GMAW but they go into some topics of interest.

Jim
1. Not all flux-core wire is self shielding
2. There is plenty of all position flux-core wire, any wire designated E71T is an all position tubular wire. E70T would be flat and horizontal only.

[W_B]

I'm in the same boat, I just bought a 130A 110v MIG, I'm using Flux because I've heard I can get a deeper weld. I don't know if there's any truth to that, I'm sure it depends on the welding technique.

What are the Main advantages in using Fluxcore-vs-Gas?

I've Used plenty if Gas MIG's for exhaust, sheet metal but that was years ago, never for anything that needs strength..

[keenavv]

Get Viagra1

[guidolyons]

If possible chamfer the edge(s) of what you are going to weld.
X2 Bevel/chamfer the edges, crank the heat all the way up, weave or do several passes until you get it all welded. It won't be as strong as a weld made with a higher amperage welder, but it will help.

Or if you are crazy like Log-jamGrant just rewire it and add a 200 amp battery charger:grinpimp:

[tennessee rockhumper]

everybody needs to be able to weld something thick from time to time, no reason to buy a big welder if its not that often.


grind a V and fill here
_____________..._____________
_____________\/_____________

[ChicksDigWagons]

Flux core will definately help, the CO2 won't hurt at all but I don't think it will improve penetration and its not needed for a self-sheilded wire.

One thing you can definately do is pre-heat your metal. A Propane or MAPP torch will do, but an oxy/fuel setup would be better. Also chamfer your edges a lot. You may need multiple passes for thick peices. I don't think most general purpose self-sheilded wire is rated for multiple passes, but if you clean the slag between passes it will be better than just laying a pretty bead on the top.

And bumping up to a .030 will also help, I don't think that little of a welder is enough to make the jump to .035 worth while.

[LCAC_Man]

Flux core will definately help, the CO2 won't hurt at all but I don't think it will improve penetration and its not needed for a self-sheilded wire.

One thing you can definately do is pre-heat your metal. A Propane or MAPP torch will do, but an oxy/fuel setup would be better. Also chamfer your edges a lot. You may need multiple passes for thick peices. I don't think most general purpose self-sheilded wire is rated for multiple passes, but if you clean the slag between passes it will be better than just laying a pretty bead on the top.

And bumping up to a .030 will also help, I don't think that little of a welder is enough to make the jump to .035 worth while.

I've run .035 flux core on my 110v lincoln with no problems, welding 3/16" and 1/4" material with excellent penitration, preheating and beveling definately helps. Good clean ground connections, running at max voltage setting, and run the wire speed as slow as you can (without it burning short), take your time working the puddle. Biggest problem will be hitting the duty cycle on the machine, and having to let it cool down.
I just bought a 175amp machine so that I don't have to deal with it anymore.

[ElPasoEric]

I've run .035 flux core on my 110v lincoln with no problems, welding 3/16" and 1/4" material with excellent penitration, preheating and beveling definately helps. Good clean ground connections, running at max voltage setting, and run the wire speed as slow as you can (without it burning short), take your time working the puddle. Biggest problem will be hitting the duty cycle on the machine, and having to let it cool down.
I just bought a 175amp machine so that I don't have to deal with it anymore.


I have a Weld Pak 100 and I use all .035 flux core. I have welded 1/4" with no probs. V cut it and then crank it up. 110v machines are real cranky when you use a small extension cord, so I would not use one if I could help it. Also it will work on a 15A breaker for the most part, but 20A will make it so much better. I think it is just mainly due to the wiring in the wall though. I find that with the flux core and setting it to setting D with wire speed at about 2.5 it works great, just my opinion. Also flux core makes my welds look su much better than with gas.

[fledgling666]

I have a Weld Pak 100 and I use all .035 flux core. I have welded 1/4" with no probs. V cut it and then crank it up. 110v machines are real cranky when you use a small extension cord, so I would not use one if I could help it. Also it will work on a 15A breaker for the most part, but 20A will make it so much better. I think it is just mainly due to the wiring in the wall though. I find that with the flux core and setting it to setting D with wire speed at about 2.5 it works great, just my opinion. Also flux core makes my welds look su much better than with gas.

there has got to be some variation in home wiring or something, i don't use "D" unless i'm doing 1/2" with my weldpak100. sometimes with 1/4" but usually, i use "C" for 1/4". i keep my wire speed just below "2" most of the time, occasionally, just above "2" and for exhaust tube- "B" and about "2-1/2" wire speed and it still burns through sometimes. i run .035 flux core wire. the only problem i am having occasionally is that i am breaking welds in the Heat Affected Zone. maybe the steel was too cold when i started the weld? hmmmm. other than that, got great penetration most of the time and can weld up to 1/2" with 2 passes.

[ElPasoEric]

1/2"? I would never think of doing anything important with a weld pak 100 over 1/4". I can do smaller stuff, but I almost never touch the wire speed, always about 2.25-2.5. I think there was a post a little while back about how to a degree higher wire speed = more heat, so I think it is best to run it as fast as it can burn. If I were going for anything more than 1/4" I always reach for the AC225.

As for wiring, around here anything on a 15A breaker is 14ga, 20A is 12ga. I ran a dedicated 20A circuit with 10/2 to my garage for the mini welder and it runs best on this line.

[SJ410Rocker]

1/2", I call bullshit. Do me a favor and weld a small piece of 1/2" together and cut it in half, let us see how well you are penetrating. You would have a hard time getting good penetration on 1/8" with a good fit.

It helps alot to get it hot before you start welding, as mentioned, with a Mapp torch.

I got a stick welder for bigger stuff. With the ac225 I have burned through 1/4" plate on 90 amps using 1/8" 6011 rod.

Little welders are just that!!

I always use maximum on my little welder and try to make holes, never works though.

[jasonmt]

Flux core will definately help, the CO2 won't hurt at all but I don't think it will improve penetration and its not needed for a self-sheilded wire.

One thing you can definately do is pre-heat your metal. A Propane or MAPP torch will do, but an oxy/fuel setup would be better. Also chamfer your edges a lot. You may need multiple passes for thick peices. I don't think most general purpose self-sheilded wire is rated for multiple passes, but if you clean the slag between passes it will be better than just laying a pretty bead on the top.

And bumping up to a .030 will also help, I don't think that little of a welder is enough to make the jump to .035 worth while.

CO2 when used with self shielded flux core filler will increase penetration because at high temperatures the carbon dioxide dissociates into carbon monoxide and free oxygen. The free oxygen then superheats the weld puddle but this comes at the expense of an unstable arc with an increase in spatter.

A larger propane torch (Tiger Torch) is commonly used for preheat and will easily preheat any mild steel weldement a home fabricator is likely to come across.
http://www.flameengineering.com/Assets/torch_images/BIG-VT-3-30-C.jpg

The normal run of the mill, general purpose self shielded flux core filler such as E71T-11 is designed/rated for multiple pass welds, most single pass rated flux core filler is either the high speed/high deposition variety or contains very high levels of deoxidizers for welding through rust or mill scale.

Using the smallest diameter of filler possible while taking care not to exceed the upper limits of its current density range ensures that you have the highest current density and thus penetration possible as well. For a 110V machine I would not use over 0.024” for hard filler and 0.030” for flux core filler as the upper limits of the current density on these fillers are above the machines maximum output. A Lincoln machine like a SP135/Weld pack 100 has a maximum wire speed of 300ipm which makes running 0.023” hard filler at much over 70 amps a loosing proposition though.