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  1. #1

    Default 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. #2
    Join Date
    Sep 2005
    Location
    Salem ,Ohio
    Posts
    3,895

    Cool

    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, Grandson of Tee Nee Boat Trailer Founder
    Metal Master Fab Salem, Oh 44460
    Birthplace of the Silver & Deming Drill
    1999 MM185 w/185 Spoolgun,1986 Thunderbolt AC/DC
    Spool Gun conversion. How To Do It. Below.
    http://www.millerwelds.com/resources...php?albumid=48

  3. #3

    Default 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.

  4. #4

    Default

    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
    Suitcase 12vs
    spoolmatic 3
    victor journeymanx2
    esab multimaster260
    esab handy plasma 550
    Makita grinders
    Lathe
    21cfm honda compressor
    f350 superduty 4x4
    Lots of bills lol

  5. #5
    Join Date
    Nov 2007
    Location
    Shattuck, OK
    Posts
    84

    Default

    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

    2006 Chevrolet Silverado 2500HD 4x4

    Proud American Ham KE5TJA

  6. #6

    Default

    Thanks guys!

  7. #7
    Join Date
    Nov 2007
    Location
    dallas tx
    Posts
    325

    Default

    Quote 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

  8. #8
    Join Date
    Dec 2007
    Posts
    157

    Default 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

  9. #9
    Join Date
    Jan 2008
    Location
    VA
    Posts
    298

    Default

    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.

  10. #10
    Join Date
    Aug 2006
    Location
    Browns Valley, California
    Posts
    1,713

    Default

    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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