changing welder to flux core

[PoorOwner]

I have some 1/4" plates and bar I want to weld together.
I had wanted to buy a 240V MIG but for now 120V welder it's all I have. It's the Lincoln 135T welder.

I normally do MIG with thin wire and 75/25 gas. Anyway, since this doesn't need to be pretty or hold liquids, I think I am going to switch to flux core.

I have attached the chart for my welder. Note it is certainly conservative because it doesn't show material like 1/8" as weldable with MIG, but I know for a fact when cranked up it gets pretty decent penetration on 1/8".

Anyway, since the chart shows 1/4 being weldable ( colored the red boxes) , I am going to give it a try, I have bought the thicker wire 0.035 and the NR-211 flux core wire just like they show, I am going to need to switch the polarity. I also would prefer to weld this one outside because I don't want to melt my racedeck., now wind does not matter anymore right?

Here is the plan, I am going to clean the area really good with a flapper wheel to grind off the "mill scale" a little.
I am going to plug in a dedicated 20A circuit with nothing else on it.
I am going to preheat the weld area to almost 300F.
I am going to do a root pass
and then I am going to zig zag a bit over it for another pass.

I am making a stand for my vise. It is possible with a big hammer I would be able to beat the weld apart on a 110V welded 1/4 material. but I think the vise would probably crack or shatter also if there was ever such force hammered on.

What do you think and do you have any tips for someone has not done Flux core before, like do I want to drag or push. I think I read something that flux core has more slag and splatter it is better to drag, but push has better penetration, I am not sure though.

Thanks.

 

[Thumper68]

I would do flux with gas, helps with penetration, weld prep is key, clean metal and a groove for the root pass, make sure to remove all slag between passes.

Other than that crank her up and burn some metal.

It's a vise stand not a life threating deal.

 

[Conductor562]

Drag with flux core unless you like making a mess of your tips

 

[Bondo]

Ayuh,.... That plan oughta work just fine,...

The tip I've got for ya is,...

Ditch the flap wheels, 'n use plain ole grindin' discs,...

I use nothin' but flux-core in my little welders for portability,...
Only my big welder in the garage uses bare wire, 'n gas,...

 

[trackwelder]

Best to drag with slag. Once your machine is tuned and you maintain your stick out and travel speed spatter free welds are possible. If spatter cleanup is a worry spray some anti spatter over the work area.

 

[rsanter]

Wind is still a potential problem.
If it's windy, don't bother.
If there is a breeze then put a couple barriers up so you are working in mostly still air

Bob

 

[gungatim]

I would do flux with gas, helps with penetration, weld prep is key, clean metal and a groove for the root pass, make sure to remove all slag between passes.

Other than that crank her up and burn some metal.

It's a vise stand not a life threating deal.

you can do flux with gas? never heard that. what is the benefit, and what polarity do you use? curious cuz I've got a bunch of flux left over from old days w/o gas I never use...if there's a decent application I'd like to use it up but hate flux otherwise...

 

[Fender1325]

If Im not mistaken flux with gas is for heavy duty applications like ship building.

OP sounds like you've got it together just fine. Bevel the material to be joined with a grinder. Do your root pass, then several other passes along both sides of the original pass and top if need be until you've filled the bevel.

Just flux wire should be fine. Chip away and steel brush slag from each pass before doing another. You'll be fine outside.

 

[sberry]

Its really a 030 machine.

 

[aka Larry]

Don't forget to switch the polarity on the machine.

 

[zkling]

Just watch the duty cycle, that is really going to be your limiting factor. Otherwise have at it. Personally I would have just ran the 030 solid. It would be a bit easier on you running multipass to prevent slag inclusions.

I would do flux with gas, helps with penetration, weld prep is key, clean metal and a groove for the root pass, make sure to remove all slag between passes.

Other than that crank her up and burn some metal.

It's a vise stand not a life threating deal.

That little machine is not capable of running dual shielded wire and running NR-211 with an external shielding is just wasteful.

 

[csp]

you can do flux with gas?

It's called dual shield and uses a different wire than your standard flux core. It's also not applicable to a small machine like you have.

 

[gungatim]

It's called dual shield and uses a different wire than your standard flux core. It's also not applicable to a small machine like you have.

thanks, appreciate the clarification. side note: My machine is a HH185 and can handle about anything I can throw at it...not the biggest, but I don't consider it a small machine at all...

 

[csp]

It's small in relation to machines which are designed with dual core in mind. It's nowhere near the size of an industrial type machine. Yours is still a hobbyist/homeowner grade.

 

[PoorOwner]

I have the anti splatter spray

Does it compromise the weld quality in anyway?

 

[gungatim]

It's small in relation to machines which are designed with dual core in mind. It's nowhere near the size of an industrial type machine. Yours is still a hobbyist/homeowner grade.

gotcha, thanks.

BTW, OP, sorry for hijacking!!

 

[csp]

Oh hell, I thought you were the OP gungatim, who has an even smaller welder!

 

[PoorOwner]

I put in the .035 nr211
I made sure the polarity is switched

Is this normal ?

Looks almost like the polarity was not switches from the amount of BB

 

[zkling]

That is nothing more than a tack. Run a few beads. Yes you will get more spatter compared to running solid wire.

 

[PoorOwner]

I figured it out
It was not feeding fast enough

I got one end done with a decent bead

When I do the other end it was getting dark and moist, and the machine seems to be struggling to put some decent puddles. Like it had not enough power and the arc had a lot of smoke from the moisture in the air.
I grinded it down and would like to cover it up not sure what to do next because it seems like I wasn't getting good penetration. I think i got rushed and the duty cycle is not enough ?

 

[Fender1325]

Turn the power all the way up. If its popping turn the wire feed speed down. If its just a faint arc coming in and out turn the wire feed up. It will sound like sizzling bacon when its right.

1/4" will take several passes with your machine. From what Im told it'll burn .030 wire better than .035, 35 burns too cold because it doesnt have the juice.

 

[Fender1325]

Also be sure to hit the weld with a stiff wire brush after each pass