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  1. #11
    Join Date
    Jan 2007
    Location
    South Carolina, Dixie
    Posts
    515

    Default

    Quote 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.

  2. #12
    Join Date
    Apr 2012
    Location
    Western Pa.
    Posts
    225

    Default 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

  3. #13
    Join Date
    Jan 2007
    Location
    South Carolina, Dixie
    Posts
    515

    Default

    Quote 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.

  4. #14
    Join Date
    Jan 2007
    Location
    South Carolina, Dixie
    Posts
    515

    Default

    Quote 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.

  5. #15
    Join Date
    Dec 2007
    Location
    alabama
    Posts
    749

    Default

    Most likely the wire has absorbed moisture in the flux.
    2, XMT's 350 cc/cv
    1, BOBCAT 250
    1, TRAILBLAZER 302
    1, MILLER DVI
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    1, HF-251 BOX
    1, S-74d
    1, S-75DXA
    2, 12-RC SUITCASES
    2, 30 A spoolguns

  6. #16
    Join Date
    Jan 2007
    Location
    South Carolina, Dixie
    Posts
    515

    Cool

    Quote Originally Posted by fabricator View Post
    Most likely the wire has absorbed moisture in the flux.
    At least the spool is empty. New one ready to use. So we'll see what happens. I ran literally tons of the former 7100 wire and never experienced issues like this.
    Mustangs Forever!

    Miller equipment.

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