Wire Welder Question

[ALHILLDIRT]

I needed a quick repair and the only wire I had left at the time had some light rust spots. Big mistake, now I apparently have some of this on the inside of my cable liner, because I'm getting uneven feed on the wire. Any recommendations on cleaning the liner, or am I out the cost of a new liner.

 

[kennyd]

You can try blowing it out with air...

 

[Bill_C]

Did you try cleaning the wire feed wheel or adding pressure on it?

Is the wire kinked? Is there still a tad bit of slag blocking or pinching the hole in the tip?

I doubt the liner is the problem.

edit: Is the wire in the right grooves on the feed wheel, and is the new wire the right size for the grooves?

 

[Sherweld]

You didn't mention whether it is plain wire with gas or flux core.

Every once in a while I run into feed issues with flux core due to variations in diameter. With .035" cored wire, I now use .040" or .045" tips which solves most of that problem. Also flux core should be fed with a serrated wheel which helps resolve varying diameter wire.

Also doubt if "dirty" liner is an issue. If suggestions so far don't help, please give more details.

Sherweld

 

[JoeL4330]

I run little cleaning and lubing pads on the wire just before the feed rollers

 

[jgrieve]

I used to work in a welding shop we would remove the liner and fill an oil pump can with a powerfull solvent. put a little rubber hose on the end of the pump can nozzle and attach to the liner. pump a bunch through then blow out with air. I think it was MEK, methlye ethlye ketone, dont remember for sure i think it causes brain damage maybee just get a new liner.

 

[F.L. Jennings]

Did you try cleaning the wire feed wheel or adding pressure on it?

Is the wire kinked? Is there still a tad bit of slag blocking or pinching the hole in the tip?

I doubt the liner is the problem.

edit: Is the wire in the right grooves on the feed wheel, and is the new wire the right size for the grooves?

I agree, the problem is usually the feed wheel. The wire pretty much fills the liner unless it has a tremendous amount of wear in it.

 

[ALHILLDIRT]

You didn't mention whether it is plain wire with gas or flux core.

Every once in a while I run into feed issues with flux core due to variations in diameter. With .035" cored wire, I now use .040" or .045" tips which solves most of that problem. Also flux core should be fed with a serrated wheel which helps resolve varying diameter wire.

Also doubt if "dirty" liner is an issue. If suggestions so far don't help, please give more details.

Sherweld

Sorry for the lack of info. I'm using .035 flux core most of the time. Top feed roller is serrated, bottom roller is set for the correct groove. Don't remember on the tip, but I didn't have feed problems until I used the rusty wire. I even removed the tip, flipped the feed roller up, and had difficulty pulling the wire through. Finally went to new wire and managed to get it to feed better after hand pulling a lot of wire through, but using the feed rollers it's still jerky. Have tried blowing compressed air through it. Anyone know what type of lubricant I could use that might help. It just seems like there is more drag on the wire going through the cable than there was before.

 

[AlanB]

I guess I am odd man out here, but if you ran dirty wire, I would tell you to pitch the liner, new tip, pull the rollers and clean them well with a stainless brush and solvent (assuming Steel rollers, I don't see which welder you have)

I have never seen a reccomended lube for the wire, and would not use one.

I don't remember what my last liner cost, but I think it was under $10 for my 15' miller gun.

I hate it when wire goes bad, and it slays me too throw it out, but, every time I try and "save" one I regret it.

 

[Sherweld]

Okay .... I have to confess that I once tried WD40 when I was struggling with feed issues (before tip change)

It made a very noticeable improvement.

I was careful to do quite a bit of non-critical welding until I felt that most of the WD40 was gone.

Sherweld