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Welding wire size?

jshultz78

Well-known member
Joined
Mar 30, 2013
Messages
211
I figured the problem out on my cheapo welder, I wasn't cleaning the metal good enough. Now it welds good. I've been using .030 flux, if I bump it to .035 will I get hotter/deeper welds? It's a Campbell hausfeld with a high/low switch. Been running high with .030 flux and doing ok.

Reason asking is the welding shop here wants $20 for a 2 lb roll of .030 and Walmart has .035 Lincoln wire for 9.00.
 
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bseant

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Joined
Dec 21, 2011
Messages
118
Location
central valley,cali
I figured the problem out on my cheapo welder, I wasn't cleaning the metal good enough. Now it welds good. I've been using .030 flux, if I bump it to .035 will I get hotter/deeper welds? It's a Campbell hausfeld with a high/low switch. Been running high with .030 flux and doing ok.

Reason asking is the welding shop here wants $20 for a 2 lb roll of .030 and Walmart has .035 Lincoln wire for 9.00.

not necessarily. you have to match the wire size with your tips on your torch too. In order to get deeper welds there's no way getting around more amps and current draw assuming your running a 110v now.
 
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thinmac

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Joined
Dec 12, 2012
Messages
68
Location
Oakland
Wire size won't necessarily let you weld hotter and deeper, but it will make your machine happier running hot. If you mostly weld pretty thick stuff and you find yourself generally running in the top third of your welder's settings, moving up in wire diameter will allow you to weld the same stuff at a lower setting. Since your welder doesn't really want to be welding in the very top of it's range, that's a good thing.

On the flip side, if you have been using your .030 and running mostly in the middle or bottom of your welder's range, going up to .035 will mean you're usually running your machine low, which is as bad as running it high all the time (in terms of consistant welding performance) If you are not running your machine at the top of it's range more often then not then you don't want to go up in wire size.

Other things to consider with wire size are heat and material deposition. Smaller wire means a smaller heat effected area (area that gets super hot), which effects your heat contraction after the weld and heat embrittlement. Also, smaller wire leads to lower material deposition, which is just how much metal you're laying down. That has a giant effect on how you weld. Welding the same joint will take longer, which can cost you time, but you get to go slower, which can make it easier to do a good job. It also means that you aren't carrying as much metal, which can make out of position welding easier. For me these factors are more important than weld settings when thinking about wire size, except if the settings for one diameter are currently way low or way high.
 

PBCampbell

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Joined
Feb 2, 2009
Messages
871
Location
WV
I looked it up online because I couldn't believe Walmart was selling lincoln wire. Price came up as instore only at $9.97 + tax. No stated specifications but picture shows a 1lb spool of multipass. Doesn't seem like much savings if your local guy is supplying the 2lb spool at $20 + tax.
 

crewchief888

Well-known member
Joined
Dec 3, 2009
Messages
13,750
Location
NW indiana
IMHO

if your machine isnt capable of at least 135-140 amps you might want to stay with .030 for flux core
you also may no be capable of running solid wire and gas without purchasing a gas kit for your machine

all depends on what you're trying to weld, and your abilities as a welder.

i rarely run solid wire/gas, even for sheetmetal work, to me it's a PITA to be switching back and forth.
most of my welding isn't on sheetmetal

i typically buy 10lb spools of lincoln wire @ home depot. local welding suppliers arent open on saturdays, and the one that is, are a bunch of Dbags.....

:beer:
 
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