Bad spool of flux core wire?

a_kelley

a_kelley

mechanical fixer
Joined
Jan 26, 2010
Location
Rutherfordton
IMG_20170123_231427.jpg
Ran out of wire, no problem, I keep a spare spool.

And welds went to crap. Way more spatter, inconsistent burn. First spool of hot max wire I've had like that. Lincoln, Hobart wire runs terribly in my AC machine. Wonder if they changed flux formulations... I guess I'll try spooling half off and see if it gets better.
 
AC ????? I don't think I've ever saw or heard of anybody attempting AC flux core. Most if not all cores wires require either DCEN or DCEP. Depends on the manufacturer and mostly if it's inner or outershield. This is a new one on me.
 
Yeah the owners manual says says it's AC. This particular wire didn't specify DC, and the previous spool was the top weld.. Liner go bad in just one change of a spool? I think it's the wire.. tried different tips. No change. Wire feed is smooth, arc just didn't burn clean. Kinda like the arc was being extinguished momentarily. I'll get another spool tomorrow..
 
Any rust on the wire?
 
Have you tried running DC? Is this dual shield? What shielding gas?
 
I had welded a lot with my Hobart, no problems with flux wire. Then welder sat for a year, maybe. It's in my dry basement. I tried welding something, & the wire kept burning to the tips. Over some time, I tried several things, with no luck. I gave it up, & used the old Stick! A couple months back, I bought a new spool at Northern, & more tips, just to use some coupons with another purchase. I finally loaded the New reel, & did some trial welding. Then I welded up a crack in my tire carrier. No Problems! I think the old wire drew moisture, or Something happened to it!
 
IMG_20170126_000559.jpg
IMG_20170126_000729.jpg
Yes it was the wire. Got a spool at HF and.... Just a flywheel coupon. Didn't touch any settings. Not that this one has a lot of settings lol. No prep was performed, just laid it to that somewhat greasy thing.
 
Flux core is a low hydrgen rod turned inside out. Inverted 7018. They have a shelf life for the most part. The really good stuff comes vacume wrapped in something like high dollar pop tart paper. Having said that, a true dc current machine makes this stuff run like butter. Kinda the same difference as running ac 7018 rod verses a really good dc machine. AC requires higher out put to do the same work as DC at the same number value.
 
I may upgrade to their 220 machine, does DC and MIG. I could add a full wave rectifier, reactor and cap and make this a DC machine... Wonder how cheap I could go that route...
 
a_kelley said:
I may upgrade to their 220 machine, does DC and MIG. I could add a full wave rectifier, reactor and cap and make this a DC machine... Wonder how cheap I could go that route...
Click to expand...
Personally, I'd leave it be and buy something with better out put. Bigger in size would,open a lot of windows and uses and over all better results.
 
If I can convert it fit $30 or so it'd be worth it, and get a bigger model. Not everyone has 220 others (well, dryers, but then I need a huge cord and most the time, I'm only welding exhaust pipe or something silly like that)
 
Yeah, I guess i could use my generator either if they don't have 220 .. I have 220 at my shop, just not always is everything at the shop. Usually if they need some welding on over 3/16-1/4 I tell them to call a local outfit with a welder on a truck.
 
WARRIORWELDING said:
Flux core is a low hydrgen rod turned inside out. Inverted 7018. They have a shelf life for the most part. The really good stuff comes vacume wrapped in something like high dollar pop tart paper. Having said that, a true dc current machine makes this stuff run like butter. Kinda the same difference as running ac 7018 rod verses a really good dc machine. AC requires higher out put to do the same work as DC at the same number value.
Click to expand...
Are you saying running DC makes this less of an issue?

I've ben having issues w/ my Weldpak 100 spattering and globbing pretty bad, and after reading this I'm getting suspicious
 
True dc is all it should run on. Period. With Cv output.
 
Certain wires are OK for AC but most are DC. Not all wire spec's whether DC or AC. I'm betting if you get a roll of HF flux core the spatter goes down significantly. I hadn't tried the other spool that I got the faulty roll swapped out for yet. You can check if it's AC output with a meter set to DC. Should see ~20-40 vdc.
 
Back
Top