Welding Question

67FBack · May 16, 2006

I am trying Mig 120V .25 wire welding w/75-25 mix on a 67 mustang inner floor support and torque boxes. Some of my welds look great. But some I get a lot of spatter, and a weld that is not very good looking. I have ground the metal clean, wire brushed other areas, changes settings, heat, wire feed rate, and still cannot get a clean weld. Is there something I am missing?

Does an anti spatter spray help?

Is the old metal a poor grade and causing this problem?

I am not new to welding, only new to MIG. (Well, I haven't held a stick in about 15 years, but still....)

Any suggestions

bigcat · May 16, 2006

what wire are you using? a good solid core wire is ER70S-6 also, double check that your gas is flowing freely while welding.

67FBack · May 16, 2006

bigcat said:
what wire are you using? a good solid core wire is ER70S-6 also, double check that your gas is flowing freely while welding.

Gas is flowing, I have it set at 15 lbs. I am using a Hobart .24

What gauge is ER70S-6?

Should I be using a .35 flux core on the bigger metal?

66Runt · May 16, 2006

Polarity set correctly?

Flux core and solid core wire use oposite polarity. Make sure you've reset your polarity to the correct direction based on the type of wire. Directions will be inside the door, and in your owners manual.

One other thing, make sure you keep about 1" of wire out past the tip so that the gas can form a shield around the wire. This is an absolute must for flux core, but will also make a difference with bottled gas.

Scott

danny clemens · May 17, 2006

Are you sure that it is 100% rust free? The only time my welding splatters is if I run into a little bit of rust or if I run out of gas. Is that 15 lbs or 15 cfm. I think it should be measured in cfm and I don't know what that would convert to in lbs. I run 16 cfm and some people say that isn't enough but it works for me. You might try using more gas and see if that helps.

302 coupe · May 17, 2006

take necessary steps to ensure that the gas isn't being blown away by a fan, breeze/draft etc. Sometimes spatter can be caused by having the wire feed too fast. Adjust the wire speed until it starts sounding like sizzling bacon while you're welding. It sounds funny, but a properly set welder will sound like that.

1320stang · May 17, 2006

I'm guessing polarity as well.....

bigcat · May 17, 2006

gas flow is usually measured in CFH, not PSI or CFM. it is measured as PSI in the bottle though....

Jester67 · May 17, 2006

67FBack said:
I am trying Mig 120V .25 wire welding w/75-25 mix on a 67 mustang inner floor support and torque boxes. Some of my welds look great. But some I get a lot of spatter, and a weld that is not very good looking. I have ground the metal clean, wire brushed other areas, changes settings, heat, wire feed rate, and still cannot get a clean weld. Is there something I am missing?

Does an anti spatter spray help?

Is the old metal a poor grade and causing this problem?

I am not new to welding, only new to MIG. (Well, I haven't held a stick in about 15 years, but still....)

Any suggestions

I would use a larger wire on these pieces .25 is good for the pans but I think you would get better results with heaver wire. And as stated above check the gas and the polarity. Make sure you purge the gun before starting the air trapped in the gun will cause splatter until the mix gets to the weld.

danny clemens · May 17, 2006

bigcat said:
gas flow is usually measured in CFH, not PSI or CFM. it is measured as PSI in the bottle though....

You're exactly right. I knew that and still typed it wrong.

1320stang · May 17, 2006

You know, another thing, I have .023" solid wire and .030" solid wire. My flux core wire is .035"

bigcat · May 17, 2006

67FBack said:
Gas is flowing, I have it set at 15 lbs. I am using a Hobart .24

What gauge is ER70S-6?

Should I be using a .35 flux core on the bigger metal?

you can get it in various sizes. the code is how the wire is made. i would not recommend using flux core wire for this application, unless it is all you have. a solid core wire would be better.

67FBack · May 17, 2006

Checked polarity. Will get a flow meter. PSI is 15. Everything is OK.

I was just wondering if the older metal had a lot of impurities?

Bullitt · May 18, 2006

the older metal has a whole lot of impurities. found that out installing my subframe connectors...

68restoman · May 18, 2006

MIG is more sensitive to contamination because of the lack of flux so the cleaner the better. I've found the the rust/paint stripper disks that you put on an angle grinder work real well for prepping metal for welding. Make sure and follow that up with some residue free solvent right before you weld. I use Acetone. I wouldn't use any type of anti-splatter spray except on the welding tip to keep it clean...

68Restoman

67 GTA · May 18, 2006

Checked polarity. Will get a flow meter. PSI is 15. Everything is OK.

I was just wondering if the older metal had a lot of impurities?

What heat and wire speed settings are you set on?

pabear89 · May 19, 2006

67FBack said:
I am trying Mig 120V .25 wire welding w/75-25 mix on a 67 mustang inner floor support and torque boxes. Some of my welds look great. But some I get a lot of spatter, and a weld that is not very good looking. I have ground the metal clean, wire brushed other areas, changes settings, heat, wire feed rate, and still cannot get a clean weld. Is there something I am missing?

Does an anti spatter spray help?

Is the old metal a poor grade and causing this problem?

I am not new to welding, only new to MIG. (Well, I haven't held a stick in about 15 years, but still....)

Any suggestions

I was having troubles too, And not being and expert I consulted the welding co. that I get my suppies from.
Their suggestion was use .30 solid wire with 100% argon gas.
It has done some nice welds with very little to no splatter.
I only use the flux covered .35 wire to do outdoor general welding.

PB

67FBack · May 19, 2006

Found 2 problems. One was my fan was just slightly blowing on the work. I didn't think it would make that much difference but it does.

Two, the metal has to be so clean. With the old stick welding, you could just heat it up and burn off a lot of imputities. But with this mig, I found I have to prepare the surfaces very clean.

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