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  • Snail Trails and Porosity

    All right welders, I am not new to this game. But for the life of me I need to know where all the "snail trails" and occasional but sometimes frequent porosity comes from in dual shield FLUX CORE wire?

    I looked at lack of shielding gas: Nope. 25 cfh
    I looked at wind or air currents: Nope. Inside the shop and no fans.
    I looked at the wire: Nope. Same stuff I've been using.. ESAB 710x.
    I looked at the material. Nope. Even ground off the mill scale.

    I was welding sched. 40 3" pipe to 1/4" flat bar using .045 710x wire at 25.5v and 380 IPM.
    Maybe a couple of you more learned folks can TS this for my old A__!
    Mustangs Forever!

    Miller equipment.

  • #2
    Glad to see you back...

    thought you were in the Keys...

    Might be a bad roll of wire....

    thought that I had heard ESAB was now marketing Chinese wire....
    .

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    • #3
      I never go below 40-45 cfh even inside. Don't push dual shield if you can help it, drag it.
      Approx. 3/4" stick out.
      Has the wire been in high humidity for a while? Just some things I've had problems with in the past.

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      • #4
        Relocated

        Originally posted by H80N View Post
        Glad to see you back...

        thought you were in the Keys...

        Might be a bad roll of wire....

        thought that I had heard ESAB was now marketing Chinese wire....
        Had a new opportunity in the Carolinas. Working Marina needed a private welding contractor. Been at it now about a year. Building mostly Anodized aluminum stuff but, like most of us, doing whatever it takes to keep the wolves at bay.
        Really nice to hear from you too!
        Mustangs Forever!

        Miller equipment.

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        • #5
          I weld .045 ESAB 710X everyday. Turn your volts to 23.3 and the wire to 233 and try it. You are too hot for the part...Bob
          Bob Wright

          Spool Gun conversion. How To Do It. Below.
          http://www.millerwelds.com/resources...php?albumid=48

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          • #6
            Originally posted by aametalmaster View Post
            I weld .045 ESAB 710X everyday. Turn your volts to 23.3 and the wire to 233 and try it. You are too hot for the part...Bob

            OK. I'll give it a try. As for the CFH... am I using enough at 25? I know my other 350P machine is set for AL only and I run 45 cfh on the 100 Argon. But I can't ever remember running more than 25 cfh on the 75/25 gas.
            Mustangs Forever!

            Miller equipment.

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            • #7
              Originally posted by captkipp View Post
              OK. I'll give it a try. As for the CFH... am I using enough at 25? I know my other 350P machine is set for AL only and I run 45 cfh on the 100 Argon. But I can't ever remember running more than 25 cfh on the 75/25 gas.
              I run 25 cfh with 75/25 on my machine. Also i use the M-25 Miller gun and when that rubber O Ring at the end of the nozzle wears out i get holes. Don't know what gun you have but just a thought...Bob
              Bob Wright

              Spool Gun conversion. How To Do It. Below.
              http://www.millerwelds.com/resources...php?albumid=48

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              • #8
                Originally posted by aametalmaster View Post
                I run 25 cfh with 75/25 on my machine. Also i use the M-25 Miller gun and when that rubber O Ring at the end of the nozzle wears out i get holes. Don't know what gun you have but just a thought...Bob
                The new mm350p came with the Bernard Q gun. I believe it's to 300 version.
                What's frustrating about it is that the other day I ran 30+ pounds of this 710x wire on a bunch of 1/2" plate projects all in one day using the same settings and had very few issues except for the occasional puff of Mother Natures breath in the shop. Today however, I was just shy of giving it a blue letter cussing.
                Mustangs Forever!

                Miller equipment.

                Comment


                • #9
                  Are you using the same cylinder as the previous day ? Some have complained about random bad fills.

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                  • #10
                    I have found that when you are over running the wire this happens. To hot, to fast or both. Try turning it down some. Gas should be fine.
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                    • #11
                      Originally posted by kize View Post
                      Are you using the same cylinder as the previous day ? Some have complained about random bad fills.
                      Nope. Same cylinder, same roll of wire...what was left of it anyway. Just different day and different material.
                      Mustangs Forever!

                      Miller equipment.

                      Comment


                      • #12
                        Snail Trails and Porosity

                        Ran into same problem couple years ago. Can't remember details on worm tracks but remember had a lot to do with heat input and some with mutipass temps. But told me didn't affect weld quality that much.
                        As for porosity, started out every now & then didn't give much thought, just grind out reweld.
                        Then on long weekend with big job & deadline got worse. More grinding than welding. Did everything could think of!! Changed out gas, tried different blend, cleaned liner, was inside shop, closed all doors, put up tent to shield, changed out wire spool to new one, pre ground everything changed grinder wheels, got better then back just as bad. Would come & go. Called my WS. He walked me through all above, no help. He then gave me phone # of a 40 year welding guru tech. Called him, he walked me through everything again including my technique & application etc. then had me check lot number on my wire (3-rolls all same).
                        His verdict, faulty wire! Explained process to make and said sometimes it happens to all makers that the flux inside is missing or light or not mixed correct in a section of wire and results in porosity.
                        Told me to call my WS and hv them check lot number on there stock, it was all the same. They called manufacture had them overnight air 2-rolls from different lot number. Put on new roll, porosity gone and so was my hair ( pulled most of it out that week).
                        He said in that style wire it happens to all manufactures at some time. Shows up sometimes just in small section of wire or at worst in a complete lot of wire.
                        Happened to me. Hope it helps. Just a thought.
                        Greg

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                        • #13
                          Originally posted by MMW View Post
                          I have found that when you are over running the wire this happens. To hot, to fast or both. Try turning it down some. Gas should be fine.
                          OK. Another of our well respected brethren also made this suggestion. I'll take this to the shop and give it a try. Brand new roll of wire sitting there waiting.
                          Mustangs Forever!

                          Miller equipment.

                          Comment


                          • #14
                            Originally posted by gnforge View Post
                            Ran into same problem couple years ago. Can't remember details on worm tracks but remember had a lot to do with heat input and some with mutipass temps. But told me didn't affect weld quality that much.
                            As for porosity, started out every now & then didn't give much thought, just grind out reweld.
                            Then on long weekend with big job & deadline got worse. More grinding than welding. Did everything could think of!! Changed out gas, tried different blend, cleaned liner, was inside shop, closed all doors, put up tent to shield, changed out wire spool to new one, pre ground everything changed grinder wheels, got better then back just as bad. Would come & go. Called my WS. He walked me through all above, no help. He then gave me phone # of a 40 year welding guru tech. Called him, he walked me through everything again including my technique & application etc. then had me check lot number on my wire (3-rolls all same).
                            His verdict, faulty wire! Explained process to make and said sometimes it happens to all makers that the flux inside is missing or light or not mixed correct in a section of wire and results in porosity.
                            Told me to call my WS and hv them check lot number on there stock, it was all the same. They called manufacture had them overnight air 2-rolls from different lot number. Put on new roll, porosity gone and so was my hair ( pulled most of it out that week).
                            He said in that style wire it happens to all manufactures at some time. Shows up sometimes just in small section of wire or at worst in a complete lot of wire.
                            Happened to me. Hope it helps. Just a thought.
                            Greg
                            Roger that. The "suspect" roll of wire had been around awhile. But we only had a few issues on a previous day on the large plate job. I attributed those issues to breezes as the shop doors were open. But yesterday....Oh I get the loss of hair thing. Extra time, more grinding than welding, etc. Eventually reset the machine to hard wire and spray to finish the work.
                            Mustangs Forever!

                            Miller equipment.

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                            • #15
                              Most likely the wire has absorbed moisture in the flux.
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