"Holes" in welds
- Thread starter bmwpower
- Start date
06wt
Well-known member
Seems like porosity from your description. Porosity can be caused by a number of things. Usually lack of gas is tghe culprit, but as you mentioned fluxcore your not using a shielding gas. So its most likely contamination of the weld, oil/dirt/rust on the base metal, or its possible the spool had something on it, unlikely but possible.
rsanter
Well-known member
first step
get away from the flux core stuff.
get some regular wire and a tank
bob
get away from the flux core stuff.
get some regular wire and a tank
bob
IDASHO
Well-known member
Flux core does fine. But the steel you are welding has to be VERY clean.
IDASHO
Well-known member
I do a lot of fab work with my Lincoln 135+, using flux core.
For cleaning questionable steel, I always opt for grinding/wire-wheel/sanding the surface instead of cleaning it with some sort of chemical.
Angle grinder, D/A sander with a fresh disc on it, and a die grinder with a wire all work great.
For cleaning questionable steel, I always opt for grinding/wire-wheel/sanding the surface instead of cleaning it with some sort of chemical.
Angle grinder, D/A sander with a fresh disc on it, and a die grinder with a wire all work great.
Yea, I used a blue "brillo" disc on my angle grinder. I thought it was nice and clean, but who knows what they put in this China metal nowadays (was fixing a metal chair.)
back2class
Well-known member
- Joined
- Jan 7, 2009
- Messages
- 2,723
Could be dirt, but my guess is too fast feed for the heat. Slow down get a good puddle and in that glowing puddle you can see any bad spots. My guess is you are going too fast and just splattering and skipping too much. Flux core is easy, but mig is easier.
tatra
Well-known member
did you try different adjustments on the helmet?.......some are too darkly set to actually get a good idea as to what the puddle is doing.......another thought may be the reidue left drom the brillo pad.....seems it's responsible for engine failures.............
nate379
Banned
Sounds like finish in the metal.
You are saying it's a chair, this a chromed leg or something like that? Sometimes the finish runs pretty deep and even though the metal looks clean it's not.
Normally it doesn't have to be super clean. Bare metal from a grinding wheel is plenty fine.
I would get some scrap steel and practice a little bit if your having trouble.
You are saying it's a chair, this a chromed leg or something like that? Sometimes the finish runs pretty deep and even though the metal looks clean it's not.
Normally it doesn't have to be super clean. Bare metal from a grinding wheel is plenty fine.
I would get some scrap steel and practice a little bit if your having trouble.
Last edited:
Pat
Member
BMWpower,
Looks like the guys provided you with a lot of usefull information. The only thing I can add that appears to be overlooked but may not be a factor, make sure that if the welder was set up for gas prior to yourself using flux cored wire, that you reversed the polarity on the machine. DCEN (DC Electrode Negative) for flux cored, DCEP (DC Electrode Positive) for solid wire with shielding gas. Without reversing the polarity the end welding results will appear similar to what you have described. Another possibility might be the flux cored wire itself. Sometimes the stuff has sat around outside in a damp garage or store shelf, and picked up moisture. This will also cause porosity. If you have not yet determined the problem you might want to try a new roll of wire from a different source. Also, I have a few smaller wire feeds along with my larger industrial sized units. I have tried a flux cored brand named US Forge in all these machines and ended up with less than acceptable results. So if you are using that brand you may want to try something better........good luck
Looks like the guys provided you with a lot of usefull information. The only thing I can add that appears to be overlooked but may not be a factor, make sure that if the welder was set up for gas prior to yourself using flux cored wire, that you reversed the polarity on the machine. DCEN (DC Electrode Negative) for flux cored, DCEP (DC Electrode Positive) for solid wire with shielding gas. Without reversing the polarity the end welding results will appear similar to what you have described. Another possibility might be the flux cored wire itself. Sometimes the stuff has sat around outside in a damp garage or store shelf, and picked up moisture. This will also cause porosity. If you have not yet determined the problem you might want to try a new roll of wire from a different source. Also, I have a few smaller wire feeds along with my larger industrial sized units. I have tried a flux cored brand named US Forge in all these machines and ended up with less than acceptable results. So if you are using that brand you may want to try something better........good luck
Last edited:
sberry
Banned
Also too slow wire feed makes for porosity with many cored wires.
Is your polarity switched to DCEN?
I switched to whatever was required per the instructions on the welder case door.
It was on gas before and my brother in law showed me how to swap it over so I did. Maybe I will recheck and snap a pict or two....
independentrider
Banned
I would use a good cleaner after you grind like "Prep" from eastwood. be careful what you spray on there, some chemicals become caustic when super heated.
GN4WHLN
Well-known member
+1
Grind and clean first. Check your ground and ground cable. Cable should be tight and the clamp clean and on a clean area.