Tips for fluxcored?

/ Tips for fluxcored? #1  

Nigelw

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Been looking for a new stick set but can't find a good one second hand or a new one that is affordably justafiable.

So, fluxcored wire through my mig it will be.

What tips can you guys give me on this??? The work is outside and mostly heavy stuff so nothing that needs be xray quality, just a few pointers on what to expect from the first arc.
 
/ Tips for fluxcored? #2  
I'm sure some of the welder experts will chime in shortly but for me when I'm running flux core the two things I always have is a chipping hammer and a good wire brush.

Flux doesn't put out as pretty of a weld as one with a shielding gas. Keep the work area brushed clean from the shield in flux and it can put out some solid welds. I also take the shielding nozzle off the tip of the gun since it's not needed. It does make it nice cause you can see the wire going directly to the seam that you are welding.

I'm looking forward to following this posts because I do 90% of my welding with flux just out of the convenience of using it and would like to see what other tips/tricks are out there.
 
/ Tips for fluxcored? #3  
Self shielded flux-core? Make sure the wire you use is for single AND multi-pass welds if you're doing heavier work. E71T-GS is what a lot of the machines come with and it's only for single pass welds. E71T-11 like Hobart Fabshield 21B or Lincoln NR211MP is a better choice as it's for single and multi-pass welds. There are even better choices but a lot depends on the particular machine you have.
 
/ Tips for fluxcored? #5  
Self shielded flux-core? Make sure the wire you use is for single AND multi-pass welds if you're doing heavier work. E71T-GS is what a lot of the machines come with and it's only for single pass welds. E71T-11 like Hobart Fabshield 21B or Lincoln NR211MP is a better choice as it's for single and multi-pass welds. There are even better choices but a lot depends on the particular machine you have.

That is good information, I was not aware of that.

I've never welded with flux core and maybe have 4 hours total welding time with mig in general. Does a flux core weld produce slag similar to stick welding? I would assume so. I have also heard mention of dual shield which if I understand correctly is running shielded wire with shielding gas. Is this correct?
 
/ Tips for fluxcored? #6  
You still need the nozzle for self-shielding flux core. The only difference is the gas comes from the wire, rather than a tank. Drop the nozzle and you disturb formation of the shield gas. The wire is more forgiving of gas loss, but it helps to have a nozzle. That said, I've done some "long shot" wire welds using flux-core where the nozzle might as well have been in New Jersey. :)

Also, you'll probably find that dragging self-shield is going to work better for you, than push. Of course, you also should push up in a vertical weld to get better penetration. Figuring out that conflict is half the fun.

Penetration is always an issue with MIG. It's not the process - it's the person. MIG will create a fluid pool and "look nice" at energies insufficient to properly penetrate and fuse. Stick requires a certain energy just to keep melting, and that will usually be close enough to cause decent penetration. That might be why some people say MIG won't penetrate: it requires a little more attention from the welder to do it right. Also, when you get into the commercial space there is a lot of emphasis on tested procedures in MIG, for that reason.

I second the Hobart wire. It's easy to find and works well. The differences between wires is small, but nuance can count on things like overhead and vertical welding. Might as well get your hand used to running decent wire that you can find anywhere. The Hobart E71T-11 fits that bill. If you shoot between 1/8 and 1/4, suggest you start with a .30 wire. Common and versatile.

Other MIG thoughts...wire size equals melted metal volume and hence proportional to heat input. The more metal you dump, the more heat you transfer to the piece. So thicker wire or faster feed will increase heat. That can be good on thick pieces, or bad for thin sections or those prone to heat stress. Again, all of this is part of the fun.
 
/ Tips for fluxcored? #8  
You still need the nozzle for self-shielding flux core. The only difference is the gas comes from the wire, rather than a tank. Drop the nozzle and you disturb formation of the shield gas.

I would respectfully disagree with this statement.

Flux core guns do not have gas nozzles.

flux core gun.GIF
 
/ Tips for fluxcored? #9  
I would respectfully disagree with this statement.

Flux core guns do not have gas nozzles.

<img src="http://www.tractorbynet.com/forums/attachment.php?attachmentid=390946"/>

And you can get a protective cap to go in place of the gas nozzle for self shielded wire. Helps keep spatter off of the gun, and reduces the chance of shorting to the work
 
/ Tips for fluxcored? #10  
Does a flux core weld produce slag similar to stick welding? I would assume so. I have also heard mention of dual shield which if I understand correctly is running shielded wire with shielding gas. Is this correct?

The slag differs as it's more powdery than hard, I almost never need a chipping hammer as the wire brush takes care of it.

Dual shield is exactly as you stated, except it is a wire specifically for dual shield.
 
/ Tips for fluxcored? #11  
Except in vertical up Flux-core is always pulled. Pushing would cause slag inclusions and just make a mess. Metal-core is pushed but it has no slag. Dual shield is just another name for gas shielded Flux-core. No nozzle is needed for self shielded Flux-core but a thread protector is usually used. Some large diameter self shielded, high deposition Flux-core uses an insulated wire guide instead of a nozzle that allows for up to 3 3/4" wire stick out from the contact tip. This preheats the wire which greatly contributes to the high deposition rate. Depending on the wire Flux-core can be straight or reverse polarity whether self shielded or gas shielded.
 
/ Tips for fluxcored? #12  
I always assumed the flux core wire was for people like me that are too cheap to set up the gas. You all have showed me a that there is a use for the flux core mig. I will have to dig out the 110 mig and reset it up for flux core, just to play sometime. Sure can learn a lot on TBN'


Thanks
Brian
 
/ Tips for fluxcored? #13  
I use the gas, and it's expensive getting kinda tired of paying for it. Also have to stop welding when the gas runs out. I will to buy a roll of flux core and try it out. (outside too!)

Very good, concise, on-topic info in this thread.
 
/ Tips for fluxcored? #14  
Haha that's funny. Same thought here, except I don't think "too cheap", people make money management decisions, and overbuying is not always good. I use gas, and it's expensive. I think I need to buy a roll of flux core and try it out. (outside too!)

Says the guy with the most expensive 120v welder out there :laughing:

In all seriousness, I too thought the same thing. Now I wonder why it's not more widely used like on pipelines. The cost per weld has got to be substantially cheaper. Maybe sometimes they do? I'm under the impression they still stick weld the pipelines.
 
/ Tips for fluxcored? #15  
Ooops edited that out Mike, but yes the Miller salesman caught me in a weak moment.:laughing: Kinda like motorcycle salesmen when one gets me the other hobby suffers a little.

It's a 120/240v MIG/TIG/Stick - very portable suitcase welder because I weld in 3 locations. Got the stick so I could weld outside in the wind, but anxious to try fluxcore too.
 
/ Tips for fluxcored? #16  
Fluxcore wire is usually more expensive than solid wire so the price for welding with gas might be cheaper overall still have to worry about running out of gas.
 
/ Tips for fluxcored? #17  
Pipelines are welded with stick, Innershield (self shielding flux-core) and automatic is done with multiple head MIG. Welding cost's can be quite complex. Flux-core costs more but is a lot faster. Sometimes production dictates the best process. Sometimes it's what's the easiest.
 
/ Tips for fluxcored? #18  
I use flux core exclusively. Not really cause it is better (it is quite smokey), but it is simply much more convenient for welding outdoors (no worry's about wind blowing away shielding gas), the 115 volt welder in much more portable minus the bottle (pick it up and easily go anywhere), and flux core gives a 115 volt unit a tad bit more oomph compared to using gas mode.

Price is close enough to a wash for an occasional user that it is no big deal (now for a business cost could be a factor). That said, I only buy the 2 lb spools (Hobart 21B) and usually wait for them to go on sale for a couple dollars off at Rural King or TSC which helps the cost factor even more. I like the Lincoln wire but it is only available in 1 lb spools in the small size which I do not like that spool size as it is expensive buying this way. I can not use it up fast enough to buy the 10 lb spools and do not want to hassle with installing and removing the spool from the machine all the time for proper storage in an effort to keep it stored properly

I do use the E71T-11 as it is suitable for multi-pass welding where E71T-GS is for single pass welding only. Single pass wire on a small wire feeder is a bad idea in my book...
 
/ Tips for fluxcored? #19  
Fluxcore is all use in the field lugging around my 12vs with 33lb spools in it will make a man of you. It's a bit more tolerant of millscale or a bit of rust, it's easy to run but you better have some ventilation because like others said it's smokey, it's basically just like a really really long 7018 rod
 

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