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Tips for the wire welder

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  • Tips for the wire welder

    How often should a guy be going through tips?I am using flux core wire and it seems that i have to replace the tip quite often because the wire will quit feeding do to all the build up of gunk.

  • #2
    Try a wiper on the wire before the rollers to catch some junk. A small piece of felt or scotchbrite and a wire clip will work. Also some of the flux may be leaking out causing the gunk...Bob
    Bob Wright

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

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    • #3
      changing tips when using flux core wire

      Make sure that you blow out you liner from tip towards drive rolls often. The build up of dust inside the liners when using flux core wire is common and it could lead you to believe that the tips are bad. Run a torch tip cleaner through you welding tip also could help. While using an automated machine, tips lasted at least eight hours of continous welding while using at least 400 amps on 3/32 dia. wire. Dust build up while using flux core wire is a lot worst that when using solid wire with gas.

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      • #4
        Whe using5/64 flux core,i only use one every couple of jobs,but i also use nozzle dip which helps to keep the spatter from building up as it wipes off easily.
        Trailblazer 302
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        Lots of bills lol

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        • #5
          I had the same problem here recently with flux-core wire in my grandpas SP-135. I was attaching some rolled wire onto some panels for chickens, the tip kept plugging up, and after several times of taking it off and cleaning it out, I got mad, fired up the old Thunderbolt and cranked her down real low, grabbed some 3/32" 7014 and went to work. This proved to work so much better. Ran out of time that day so brought the panels into school the next day and finished them with a MM210 (.035 wire, 100% CO2). After this experience, I wasn't to impressed with the flux-core process. I guess like everything else, it takes some getting used to.
          At Home
          Miller Thunderbolt XL AC/DC
          Performance Tools 6" Bench Grinder
          Craftsman Hand Tools
          Craftsman Cordless Drills

          DeWalt Angle Grinder
          1976 AMC Jeep CJ7
          1980 Ford F150 Custom
          1994 Chevrolet Silverado C1500

          At Work
          Miller Bobcat 250
          2 Miller MM251s
          2 Miller MM252s
          Miller Dialarc 250 AC/DC

          Lincoln Idealarc 250 AC/DC
          Snap-On Flux Core Welding Machine

          Hypertherm Plasma Cutter
          Victor Torches

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          • #6
            Thanks guys!

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            • #7
              Originally posted by bryce_burden View Post
              I had the same problem here recently with flux-core wire in my grandpas SP-135. I was attaching some rolled wire onto some panels for chickens, the tip kept plugging up, and after several times of taking it off and cleaning it out, I got mad, fired up the old Thunderbolt and cranked her down real low, grabbed some 3/32" 7014 and went to work. This proved to work so much better. Ran out of time that day so brought the panels into school the next day and finished them with a MM210 (.035 wire, 100% CO2). After this experience, I wasn't to impressed with the flux-core process. I guess like everything else, it takes some getting used to.
              ..................MM210 will spoil you ....you will see when you go back to flux core...
              was used to using nice welders at work ,and was always taking stuff into work to fix/break it .then i go home and weld with my 90 amp fluxcore machine form harborfreight(yeah its blue ,but it aint the same), and im like ....dude this thing sucks. it makes me wanna sell my truck to but a welder ,then i think about how well i can drive a welder home from the bar at 2oAM
              my daddy always said i was IRONHEADED....
              feel free to P/M me

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              • #8
                Flux core

                I have done a bit of welding with a mm180 and flux core wire. What I noticed right away is that it really doesn't like the hose to be curled at all. As soon as you loop or curl the hose it slows down the feed which usually welds the wire to the tip.

                There must be more drag on the liner than with the solid wire.

                I went to great pains to maneuver the unit in such a way that the line was as straight as possible and then no problems...
                John

                Thunderbolt AC/DC
                MM 175
                Maxstar 150 STL
                Blue Star 185 DX
                Spectrum 375

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                • #9
                  I don't know about the 180 but my 135 calls for a larger liner when using flux core. One for .023 and one for .030 and .035 IIRC. That might have been the problem.
                  Weekend wannab racer with some welders.

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                  • #10
                    Another common feeding problem with cored wires is too tigh of a wire feed tension adjustment.

                    The construction of the wire is such that too much tension on the feed roller will egg the wire. When that egged section hits the tip, it either won't feed at all, or it slows down. That usually results in burn back and a ruined tip.

                    Pop your wire out of the drive and look closely at it with a magnifier.

                    Hank
                    ...from the Gadget Garage
                    Millermatic 210 w/3035, BWE
                    Handler 210 w/DP3035
                    TA185TSW
                    Victor O/A "J" series, SuperRange

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                    • #11
                      Egg..

                      Thanks Hank, never thought of that.
                      John

                      Thunderbolt AC/DC
                      MM 175
                      Maxstar 150 STL
                      Blue Star 185 DX
                      Spectrum 375

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