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Old 03-17-2020, 08:14 PM   #1 (permalink)
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Porosity in welds

Been having an issue with porosity in welds. Go to welder is a Miller 211. Using 75/25 gas and .030 wire. No matter how clean the metal is I'm getting it. But the thing is it's not all the time. You can weld once and it will be fine. Then go again and it's bad. This is on the same piece of metal. I've changed the regulator for a new one. Made sure the lead is tight in the machine. I'm at a loss. The machine is a few yrs old. Never an issue before.
Anyone had this issue? TIA.
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Old 03-17-2020, 08:17 PM   #2 (permalink)
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check the o rings where the mig gun plugs into the machine. lub them with spit as you slide it back in as to not pinch them. Giggity.
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Old 03-17-2020, 08:18 PM   #3 (permalink)
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check the o rings where the mig gun plugs into the machine. lub them with spit as you slide it back in as to not pinch them. Giggity.
I was wondering about that .Will do tomorrow.
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Old 03-17-2020, 09:21 PM   #4 (permalink)
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wire brand? recent change?
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Old 03-17-2020, 09:46 PM   #5 (permalink)
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Check the wire for rust.
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Old 03-17-2020, 10:30 PM   #6 (permalink)
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I have a Miller 180 I've had for over 20 years. I had to replace the solenoid valve when it was new. I don't remember if it caused porosity or if it just wouldn't shut off but that might be your culprit. It might not be opening each time you start welding.
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Old 03-18-2020, 12:50 AM   #7 (permalink)
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I have a Miller 180 I've had for over 20 years. I had to replace the solenoid valve when it was new. I don't remember if it caused porosity or if it just wouldn't shut off but that might be your culprit. It might not be opening each time you start welding.
We have a milller 250 that every 50th time or so gas will not flow when you start the weld. Stop and restart usualy fixes it..
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Old 03-18-2020, 05:44 AM   #8 (permalink)
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Make sure that the shielding nozzle is making a good seal and isnít allowing room air to draw in from behind. Some have nozzles have a rubber or plastic seal. Some have a felt seal. Remove the nozzle and make sure everything looks good.
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Old 03-18-2020, 06:27 AM   #9 (permalink)
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Presumably you are welding inside without doors open or fans blowing?
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Old 03-18-2020, 10:25 AM   #10 (permalink)
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I have similar issues with my 211. For me, I have to clean out the tiny gas orifices under the nozzle. I use a piece of wire or a torch tip cleaning rod and push it into the holes - no spit required. I don't know if it's crap from the bottle or weld splatter. Good luck.
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Old 03-18-2020, 12:10 PM   #11 (permalink)
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Quote:
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check the o rings where the mig gun plugs into the machine. lub them with spit as you slide it back in as to not pinch them. Giggity.
This is the first thing I check. The cap at the wire entry end of the whip sometimes backs off if not screwed on tight enough.
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Old 03-18-2020, 02:00 PM   #12 (permalink)
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Flux core dont do that shit

And quit pinching the cord.
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Old 03-18-2020, 02:34 PM   #13 (permalink)
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I was talking to a the counter guy at my local Airgas one day about shielding gas making nasty fumes (my welds were fine but the fumes it made would choke you out). He said he hadn't heard of anything like that but had heard of oxygen contaminated 75/25 causing porosity. I switched out my cylinder and my nasty fumes were gone.
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Old 03-18-2020, 04:28 PM   #14 (permalink)
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Flux core dont do that shit

And quit pinching the cord.
I use flux rarely and am careful of not bending the lead. I just put a new roll of wire in. It was doing it before also. Wire doesn't have time to rust on me.

I pulled the lead. One of the orings had a nick. Ordered new ones. I did grease the old ones a little and did a few test welds. Seems to work fine. I didn't have any welding projects today to really test it.
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Old 03-18-2020, 04:29 PM   #15 (permalink)
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I was talking to a the counter guy at my local Airgas one day about shielding gas making nasty fumes (my welds were fine but the fumes it made would choke you out). He said he hadn't heard of anything like that but had heard of oxygen contaminated 75/25 causing porosity. I switched out my cylinder and my nasty fumes were gone.
This is interesting. I did just get all of the cylinders exchanged.
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Old 03-18-2020, 04:32 PM   #16 (permalink)
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Presumably you are welding inside without doors open or fans blowing?
Inside usually but do have an exhaust hood above the welding table. But this just started happening. So I doubt it's that.
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Old 03-18-2020, 07:41 PM   #17 (permalink)
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I was talking to a the counter guy at my local Airgas one day about shielding gas making nasty fumes (my welds were fine but the fumes it made would choke you out). He said he hadn't heard of anything like that but had heard of oxygen contaminated 75/25 causing porosity. I switched out my cylinder and my nasty fumes were gone.
Yes this also^ I just had to exchange a bottle of argon that just would not weld aluminum clean. New bottle welded great.
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Old 03-19-2020, 11:11 AM   #18 (permalink)
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Been having an issue with porosity in welds. Go to welder is a Miller 211. Using 75/25 gas and .030 wire. No matter how clean the metal is I'm getting it. But the thing is it's not all the time. You can weld once and it will be fine. Then go again and it's bad. This is on the same piece of metal. I've changed the regulator for a new one. Made sure the lead is tight in the machine. I'm at a loss. The machine is a few yrs old. Never an issue before.
Anyone had this issue? TIA.
I have this exact issue with my hobart 210.
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Old 03-19-2020, 11:14 AM   #19 (permalink)
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Have you guys looked into your ground?

A look at the cable going into the lug in your clamp.
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Old 03-19-2020, 06:13 PM   #20 (permalink)
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I have this exact issue with my hobart 210.
Interesting. I have a Hobart 210mvp that I have been having intermittent porosity issues with as well.
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Old 03-19-2020, 07:38 PM   #21 (permalink)
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Have you guys looked into your ground?

A look at the cable going into the lug in your clamp.
I haven't. Seems to be working fine most of the time now. Co worker welded up a stand and most welds were fine with exception of a couple started good but changed part way through. We changed the cone on the lead. The one we had on seamed a tad short. The tip was sticking out a touch. But I don't think that did anything. Hopefully new orings will fix it.
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Old 03-20-2020, 06:31 AM   #22 (permalink)
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Interesting. I have a Hobart 210mvp that I have been having intermittent porosity issues with as well.
One good inch, I stop, one bad inch. It was very frustrating when some of my tabs look like I was drunk using a buzz box.
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Old 03-26-2020, 09:38 AM   #23 (permalink)
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What wire are you using? I've never had purosity or spatter problems up until about 3 months ago when the local harbour frieght started carrying 33lb spools of wire. Nobody stocks it withing a 40min drive of me so I bought it and have had nothing but problems since. I just switched back to hobart brand wire and the problem went away instantly
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Old 03-26-2020, 10:46 AM   #24 (permalink)
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get one of these flow meters, its an easy way to know your getting enough gas at the weld puddle.

https://www.amazon.com/Professional-...5244666&sr=8-4
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Old 03-26-2020, 05:50 PM   #25 (permalink)
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What wire are you using? I've never had purosity or spatter problems up until about 3 months ago when the local harbour frieght started carrying 33lb spools of wire. Nobody stocks it withing a 40min drive of me so I bought it and have had nothing but problems since. I just switched back to hobart brand wire and the problem went away instantly
Radnor 11lb spools from Airgas. Been using that for yrs. Easy to get for us.
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