Having problems with my MIG setup

[rbahr]

Hi All,

Or perhaps me!

It has been some number of years since I last did any welding, and even then I never did much!

I have a Millermatic 211, running @220v, .035 solid core wire, 75/25 gas. I am welding steel 16ga square tubing. My settings are right where the welder suggests, the wire tension seems good, The gas flow rate seems to be where recommended - though I will check again.

I have been trying a number of things and am still having problems. This AM I cleaned the metal, redid the ground connection, shortened the stickout, and am getting welds like this, brown soot is new from the weld. There is a lot of sputtering and popping. When the wire 1st makes contact some really bright flashes.

Any help would be greatly appreciated

 

[DieselNut88]

Are you sure the gas is on? That is what happens to me if i forget to turn on the gas. I have the same welder.

 

[rbahr]

Yep, gas is on, checked all the connections,

This is a new to me welder, and so far, the PO was kinda a hack. The welder has .035 wire, and the tip was a .030 tip, that someone tried to make work. I replaced it with a new tip, reset the tension, and played with some speeds and voltage. Now I am getting welds that have a crater at the end, and frequently burn through - 2nd picture here. It is also still sputtering

Thoughts?

 

[snyder]

1. Are you using solid core wire?
2. Turn the wire speed and voltage down, do you feel gas coming out of the tip?
3. Are you purging the nozzle before you start welding.
4. No fans or wind to blow the gas away?

 

[rbahr]

Yes, solid core .035, 16ga steel
Been trying a variety of speeds & voltages - withing the recommended values the machine has listed.
WRT purging - by that do you mean making sure there is gas flow? I am not doing that.

There is some mild win - I am in my garage, but the door is open...

Thanks

Ray

 

[Kaizen]

Agree turn down settings so less of a puddle and no burn through. Does that welder have reverse polarity? Make sure your gas maintains pressure while pulling the trigger


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[snyder]

By purging , i mean to get rid of the air that fills your mig hose after your machine sits idle for a while. If you dont purge it out , there will be no sheilding gas on your weld when you start.

 

[east_tn_emc]

Double check the polarity....reverse polarity for gas and straight polarity for flux core wire. They typically come set for straight polarity from the factory.

 

[DieselNut88]

Do you hear the gas solenoid clicking? I have read about the boards going bad on some 211's causing no gas flow. A relay on the board goes bad.

 

[American Locomotive]

Gas is on, but are you sure you're getting gas at the nozzle?

 

[MarkG]

You're not getting gas coverage and/or your polarity is wrong or you didn't get the metal clean! Are you SURE you are using solid wire and don't still have flux-core in there? If you have ALL those and still have problems, the problem probably can't be diagnosed 'remotely' on an online forum! :S Let us know what happens.

 

[Warrenator]

hold the weld nozzle up to your ear, make sure you hear and feel a hiss of gas when you pull the trigger.

 

[rbahr]

All good suggestions! - I am positive that I have solid core wire, and I am certain about the polarity. I do need to check the gas flow - I have been using it - I can see the tank go down with all the playing I have done. I will start taking things apart and verify the gas line, etc.

I did clean the metal with sandpaper - put it on a belt sander and got it pretty clean.

I do hear a solenoid or relay engaging, but that could just be the spool motor...

Thanks

Ray

 

[BD1]

Besides the above, A flat flapper disc on a 4 1/2'' grinder works well for cleaning.
Check wire spool for correct orientation , tension setting, and manual for basic setup and settings. Mig with gas requires a CLEAN surface for GROUND too besides the welding area.
Some inexpensive wire does run poorly but is usable. The 211 runs best with .030 wire from my experiences and others from the Weldingweb site.
https://weldingweb.com/search.php?searchid=31413837

 

[rbahr]

Thanks BD1,

I plan on changing out the liner, will likely replace the gas, might look into a spool of .030 wire while I am at it.

Ray

 

[fnieto]

That machine will run .035" just fine. It's apparent to me the shielding gas is not reaching the nozzle. You should be able to hear and feel the inert gas flow at the nozzle. Don't go out and buy .030" until you correct the shielding problem. Trace the gas hose and look for issues. Replacing a damaged liner will also help. If you decide to change wire size, use the correct push roller grooves.

I would unplug the machine, remove the skins and inspect the machines looking for obvious gas flow problem. Use low pressure air to blow out the insides while your at it.

Not sure why you would replace the gas, I've never seen noble gasses spoil.

If your wire is old and has surface rust, it could cause this kind of issues. The wire should look like shinny copper. If you live in a humid environment and don't weld often, I suggest removing your spool and storing it away from the humid environment. The surface corrosion will eventually foul the liner and produce **** welds.

From you last photo, I'm betting your not getting all the gas to the nozzle.

 

[LXCam]

Definitely not getting any gas. And for the little bit of work you're tested shouldn't see any drop of volume out of the tank. Sounds to me like you've got a major leak somewhere so I'd suggest exactly what's already been suggested. Tear it down and inspect and repair.

 

[Bopbop]

What is the flow rate on your gas? Could be low. The weld looks like it does not have gas to it. Check for leaks. Been there with that issue, I bad o ring. Also the weld does look like solid core wire.
The machine is a good piece of equipment typically.

 

[scooby074]

You can buy flow meters that stick in the end of your gun for testing. I think youre getting enough gas but they are cheap.https://www.amazon.com/dp/B01M5H1228/?tag=atomicindus08-20

How old is your wire? Is it rusty? Try some new stuff from a good brand like Lincoln anyways. Change your liner. Clean and check your drive rolls.

 

[Jack Olsen]

Following.

I have a 211, and a similar problem. The last time I used it I could see flow at the meter, but I think I was losing gas between the meter and the nozzle. I switched over to flux core to get through the work at hand, but I'm going to go back and see if I can locate a possible leak.

 

[Stooge]

I seem to remember the liner in my 211 wearing out prematurely and giving me some grief, although I don't think it was as bad as what your seeing. Unscrew the lead end at the machine to check out the sealing o-ring's condition, and I hate to say replace the liner as it could just be throwing parts at it, but theyre pretty cheap, and would help narrow down possible issues. Have you checked the diffuser under the nozzle, just a shot in the dark, but maybe its caked up and not allowing the gas to flow as freely?

 

[sanddan]

I think you are getting gas flow based on the weld bead, no porosity. I've seen the brown smoke on the steel before, usually was due to old, tarnished wire. Having a breeze in the work area could also be the cause. Some of the gas coverage is diluted by the breeze. Shut the door, make sure the gas is at a min of 15-20 cfm and try a new spool of wire. For 16 ga I would not use thicker wire than .030" even tho the chart will have a setting for .035". It just seems to weld better for me on thinner material.

 

[Slednut]

I don't know if the OPs 211 has a process select control knob, if it does could this be set wrong? I bought a 211 two years ago and it has the knob.

 

[MoonRise]

Some things to check (or double-check):

- check polarity. Make sure that is is set for solid-wire GMAW and not for flux-core FCAW.

- wire on spool rusty/crusty? If so, toss it.

- name brand or no-name wire? I'm not a good enough welder to use no-name wire.

- the correct shielding gas in the cylinder? It should be C25 (75% argon and 25% CO2). Some other shielding gases can be used for short-circuit transfer mode GMAW, but that is the 'best' and most common gas to use. No, you can NOT use 100% argon for GMAW on steel.

- you MUST use the correctly sized contact tip AND wire-drive rollers for the wire size you are using. You can NOT use an 0.030 contact tip with 0.035 wire. You can also not use an 0.035 contact tip with 0.030 wire.

- torch liner/conduit the right size for the wire being used? Most of the 'small' MIG machines that I know of (like the MM211 or other name brand similar power machines) usually have an OEM 0.035 conduit, but someone could have changed it.

- double-check ALL the gas connection fittings. Tank to regulator, regulator to hose, hose to machine, torch cable to machine on the front (make sure that the O-rings are in good shape and that the torch connection fitting is properly inserted ALL THE WAY into the fitting block on the machine). Use some leak-check solution. Check the condition of the torch cable hose as well, sometimes they can get damaged (spatter, running over with the cart casters, dragged across a sharp metal edge, elephant stepping on it, that sort of thing )

- check the condition of the gas diffuser. Clogged up with spatter or slag and it won't properly let the shielding gas flow through to the weld zone.

- Do NOT-NOT-NOT put the welding torch up next to your ear and pull the gun trigger to 'check' for gas flow! You can put welding wire into your ear.

-the weld bead ending crater is due to technique. You have to pause at the end and then slightly go back into the existing weld bead to not have an ending crater. That is the least of your problems at this point.

- usual shielding gas flow for 'small' machine GMAW is 20 cfh. More is not better, less may not be quite enough.

- check the copper nozzle to make that it is not all crudded up with spatter and slag on the inside

 

[gordo9742000]

What is your setup as far as tip and nozzle? Is it protruding or is it recessed?

 

[aka Larry]

I know everyone here is suggesting no gas flow, but when I forget to turn the gas on, my welds have a ton of porosity, which is not what I'm seeing in those pics. All the soot looks like you were using flux-core though.

 

[jeepinerdeep]

Is your liner full of rust?

 

[rbahr]

Hi All,

Thanks for all the help. Problem was the liner was bad. I changed out the liner, replaced the gas and it was as if I had a new machine.

Ray