Miller Electric

Welding Discussion Forums

Home » Resources » Communities » Welding Discussion Forums

The forum is currently undergoing maintenance and is in a 'read-only' mode for the time being. Sorry for the inconvenience.


  • If this is your first visit, be sure to check out the FAQ by clicking the link above. You may have to register before you can post: click the register link above to proceed. To start viewing messages, select the forum that you want to visit from the selection below.

Announcement

Announcement Module
Collapse
No announcement yet.

Flux Cores getting me down...

Page Title Module
Move Remove Collapse
X
Conversation Detail Module
Collapse
  • Filter
  • Time
  • Show
Clear All
new posts

  • Flux Cores getting me down...

    I Usally run a millermatic 212 set up with .035 hard wire and a 75/25 argon co2 mix at work. Works great but every once in a while i'll have to run flux core because I'm outdoors. I reversed the polarity, put in knurled drive wheels and put in a fresh liner. Now comes my problems. 1 as I'm welding the wire will just stop feeding. usually with mig i just flick the lead and the wire will pop out. With FC the wire gets all rats nested inside the machine. I loosened the clamp on the wire and make sure I have a new tip but it still happens mid weld instantly. This happens once in a while running mig but with FC it's like every half hour. Any ideas would be greatly appreciated. My other issue is on thinner steel I'm getting holes in my welds. kind of like perosity i guess. When i run mig I can use the same tip all day, FC i'm using about ten.. Is this typical of FC?

  • #2
    I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

    What size wire & settings are you running?

    Comment


    • #3
      I wouldn't trade solid wire w gas for non gas flux core. I weld outside too and use cardboard shields and tarps to block the wind. I just don't like non gas flux. Thats just me prob and i am sure someone who likes it will chime in.
      Now i run gas flux at work all day everyday and i use lots of tips and have birds nests about once a day but the biggest prob is the company bought aftermarket tip adaptors and they are just too long and i spend lots of time grinding dow 1/2 of a new tip. Think i will take some home and wack them off in my lathe and do a proper deburring of the end...Bob

      Comment


      • #4
        Originally posted by MMW View Post
        I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

        What size wire & settings are you running?
        Are your drive wheels knurled? I think smooth would be better...Bob

        Comment


        • #5
          Flux Cores getting me down...

          Sounds to me like the spool is not locked in to holder or tension is too loose. I never ran flux core in my 212 but with hard wire I have never had it birds nest in the mech. The spool has to be over rolling the feed.

          Comment


          • #6
            Originally posted by go2building View Post
            Sounds to me like the spool is not locked in to holder or tension is too loose. I never ran flux core in my 212 but with hard wire I have never had it birds nest in the mech. The spool has to be over rolling the feed.
            I run gas flux in my MM185 with zero problems but mine has a single wheel drive and a smooth wheel where i think the MM212 has two drive wheels, just not sure...Bob

            Comment


            • #7
              flux core

              Originally posted by MMW View Post
              I run a lot of flux core gasless wire known as innershield. Using .045 mainly Hobart 21B. I don't have that problem. I set the drive roll tension just enough so it doesn't slip when welding but if it gets stuck it will slip slightly instead of birdnesting. Very rarely does it get stuck. I assume you are using the same gun for both wires & you blow it out when switching? I keep my nozzle on for both types of wires. My gun is 15' with a .045 liner.

              What size wire & settings are you running?
              I'm running 035 with a 15' miller lead. Are you suggesting i use a 045 liner with the 035 wire? i have my clamp as loose as it will go thats why i just dont see how its rats nesting so quick... I put a brand new liner in it when i switched to the flux. do you think the knurled wheels are pushing the wire to aggrsively. when i run mig its like you said it will slip and not tangle. its so frustrating.

              Comment


              • #8
                Flux Cores getting me down...

                As far as tips you could have the rollers too tight crushing the wire

                Comment


                • #9
                  Page 9 has different drive wheels for your machine. I am going to try the mix and match at work tomorrow...Bob
                  http://www.millerwelds.com/om/t232385e_pt_mil.pdf

                  Comment


                  • #10
                    reply

                    Originally posted by aametalmaster View Post
                    I run gas flux in my MM185 with zero problems but mine has a single wheel drive and a smooth wheel where i think the MM212 has two drive wheels, just not sure...Bob
                    this could be the problem because im running a 10 pound spool. Usually with the hard wire i run 30 pound spools. Am I supposed to have an adapter of some sort? the smaller spool just slides back and forth in the machine.

                    Comment


                    • #11
                      Originally posted by apg1984 View Post
                      its so frustrating.
                      Yup i have a brand spanking new MM251 with a 15' gun and i hate it. If it was mine and not the companies i would trade the 15 footer in a minute. I weld in a small area and i can't always keep the lead straight...Bob

                      Comment


                      • #12
                        Originally posted by apg1984 View Post
                        this could be the problem because im running a 10 pound spool. Usually with the hard wire i run 30 pound spools. Am I supposed to have an adapter of some sort? the smaller spool just slides back and forth in the machine.
                        There should be a large 2" id spring about 3" long to use with the small 10# spools. I have an extra one if you don't have it...Bob

                        Comment


                        • #13
                          drive wheels

                          I think the Knurled wheels are for a harder wire that
                          i'm using. Would you suggest u-groove or v-groove?

                          Comment


                          • #14
                            Flux Cores getting me down...

                            There is a nub on the back of the spool holder, if the spool is not tight to the back it will free wheel and over run the rollers causing a birds nest. I would never run smooth rollers on flux core it will not run with consistent speed, you can not get the rollers tight enough on flux core with smooth rollers with out crushing it and making it out of shape, the reason they don't run smooth rollers on aluminum and flux core!!!

                            Comment


                            • #15
                              I have ran fc on my 252 using .035 wire with the u notched rollers and it works great, but from the sounds of it u definitely need the adaptor to use the 10 lb roll, the adapter is basically just a spacer too keep the roll snug to the wall of the machine so the roll can work as intended, I would strongly recommend checking the wire inlet guide, after a while the wire wears it out and it causes the birds nest effect, more so on fc and stainless, if you are using the plastic one that came with the machine I would recommend upgrading to the brass one

                              Comment

                              Working...
                              X
                              Special Offers: See the latest Miller deals and promotions.