Weld sputtering and smoking?

[madosta]

So I just put together me a new Bernard Q-300 with Centerfire consumables, but I'm having some issues with my welding.

Miller MM200
60% Speed
High 2
40-50 on the gas flow, 75/25 argon co2 mix.
.030 wire which is kinda old and dirty, oxidized. I have yet to pull about 5lbs off of it.

It sounds OK, but its spitting and smoking as you can see.


Grr:


New tip, just the tip:

 

[RivennHewn]

Are your power leads coming into the machine switched for no-gas operation?

 

[koditten]

My first impression is that the wire is flux core. Are you sure its solid? As said above check to see if polarity is correct.

 

[taumac]

That bead looks like a flux core wire on the wrong polarity? I've done it before. Never done it on solid wire the yet to know. Im thinking its a polarity issue to.

 

[PugetDude]

+3 on the polarity.

 

[Dave in Ozark]

^+4.... But 40-50 on gas flow? Seems high

 

[madosta]

No its not flux core wire and polarity is correct. This was welding fine before.

 

[gungatim]

same gas or did you just fill? maybe contaminated?

 

[MP&C]

I think the gas flow at such a high level is having a venturi effect of sorts in that it is pulling in air from the surrounding area. Try about 18-20 on the flowmeter and see if it changes the weld.

 

[Rlfd213]

Turn your gas down. It should be about 20 when its flowing.

 

[mustange70]

.030 wire which is kinda old and dirty, oxidized.

This, get a new spool.

The gas flow won't cause your issues, just wastes gas.

 

[kf4zht]

Make sure where the gun connects to the machine is seated right. My 175 will move slightly if you pull on the lead, then the welds go to ****. an Oring ends up where the gas should flow

 

[taumac]

No its not flux core wire and polarity is correct. This was welding fine before.

I didn't say it was flux. I said this

That bead looks like a flux core wire on the wrong polarity? Never done it on solid wire the yet to know. Im thinking its a polarity issue to.

If ever welded with flux with wrong polarity you get bead that looks the same.

 

[MJD1]

This, get a new spool.

The gas flow won't cause your issues, just wastes gas.

Agree on the wire. Excess gas flow will cause turbulence and draw in excessive unshielded air.

 

[rsanter]

I think the gas flow at such a high level is having a venturi effect of sorts in that it is pulling in air from the surrounding area. Try about 18-20 on the flowmeter and see if it changes the weld.

This was my though as well

Bob

 

[mustange70]

Agree on the wire. Excess gas flow will cause turbulence and draw in excessive unshielded air.

No porosity, that's why I doubt this is an issue.

 

[tractordude]

Fold-up a 1/2 of a paper shop rag and attach it with a clothespin on the wire before it feeds in to the rollers.

It with help with oxidation on the wire. I do this often in the summer time when its humid.

 

[2004.5cumminsman]

Looks like galvanized steel to me...grind it clean and try again.

 

[madosta]

I pulled about 1lb of wire off and started seeing some shiny wire and turned the gas down.

Not sputtering at all now.



Yea it's hot, but I haven't used this MM200 much on the high settings and was wondering if it was something to do with the "high side". Love this new gun!

 

[madosta]

Well I welded some more with different settings and I'm having inconsistent wire feed.

This was some 1/4" to 1/2" (High 2, 60%, gas at 20)


What is the rootbeer chocolate milk??

This was some 14ga (Low 5, 35-40% wire, gas at 20):


Running longer:


I think I'm going to take my drive rolls out tomorrow and inspect and clean them and get some more clean wire.

What is that chocolate milk looking liquid?

 

[mike13u]

The brown stuff isnt a big deal. Slow your wire speed down just a bit and bring your torch more upright. Many times excessive spatter comes from too much wire speed. If you drag the torch angle too far down or you have the torch too far from the puddle you will get some of that brown dust. Bring it more upright (slight angle) and closer in.
You are close

 

[Tinner]

What is that chocolate milk looking liquid?

Silica. Perfectly normal, don't worry about it.