MIG welding thin steel

[WilliamTO-35]

I've been using my MIG welder as a flux core welder, with no shielding gas, for several years. I do ok with steel thicker than 14 gauge, up to about 1/8 inch thickness. My problem has been burn through with anything thinner than 14 gauge. I've tried different thickness wire, and different wire speeds and currents . This summer, I'm going to buy a bottle of gas, and try using the machine as a true MIG welder. I have some concerns, though. One is that the visibility of the welding process is great with flux cored wire, but poor using a gas nozzle. I'm also concerned that using the gas may not solve the burn through problem as much as I expect, and that I'm doing something else wrong . Any suggestions ? Thanks.

 

[Shield Arc]

It really gets down to how well you can set the Mig welder. Far as volts, and wire speed / amps.
Here is a calculator by Miller that should help you get close.
Weld Setting Calculators - MillerWelds

 

[yomax4]

What size flux core were you using? you can get it in 030. I hate it though. You will love 023 hard wire with gas on thin metal. Hopefully you have variable amperage control.

 

[ctrider]

I'm not sure what you have for a welder or helmet. I have used the flux core very little on my Miller 211. There's just a huge difference using C25 for me anyway. I'd also suggest an auto darkening helmet. You can adjust the sensitivity and shade on most of them. I can see the puddle and arc quite well even with very thin metal. The thinnest I have tried and welded successfully is this grille on my JD MC dozer I'm trying to restore. It's probably 22ga and very small pieces. I actually cut out some of the grid from another grille and welded it in where there were gaps and breaks in this one. It was obviously a low setting, I just used the auto set feature on the 211.

 

[flingwing1969]

I'm afraid you'll simply have to go to MIG and get away from FCAW for thin stuff it is simply too difficult to do with .030 wire. As YomaX4 said, you will love MIG and .023 for your project, turn down your heat and reduce your feed, keep your stickout short, and move quickly to minimize heat deformation. I like to move my spot to keep the Heat Affected Area to a minimum on thin stuff - like a 16" piece, tack quickly on one end, move to the other, tack in the middle then go back halfway between the middle and the top weld, etc. You might also want to keep an air gun nearby to air cool welds before moving one to minimize movement - you will get some for sure, just try to minimize. Play with some sample pieces and you will really get so you love MIG. Now TIG, you would really warm up to for the tough welding jobs.

 

[dragoneggs]

What size flux core were you using? you can get it in 030. I hate it though. You will love 023 hard wire with gas on thin metal. Hopefully you have variable amperage control.

Been running .030 exclusively with my 211MVP. I don't do so good with 14g or less, either. I guess I have to go through the hassle of swapping out wire to .023... or get a new welder!

 

[tomplum]

Been running .030 exclusively with my 211MVP. I don't do so good with 14g or less, either. I guess I have to go through the hassle of swapping out wire to .023... or get a new welder!

I hear you. It's so dang bothersome having to change wire when you could just have one set up ready to squeeze the trigger. Let's see, a little blue one for .023, a red one for .030, a green one for 045, maybe a maroon one for .035. Just like grinders....

 

[dragoneggs]

I hear you. It's so dang bothersome having to change wire when you could just have one set up ready to squeeze the trigger. Let's see, a little blue one for .023, a red one for .030, a green one for 045, maybe a maroon one for .035. Just like grinders....

Except it is much easier to build a fleet of grinders! :drink:

I like your color coding idea, though!

 

[BotaTrac]

You're a better welder than me!

 

[MickeyDBC]

I used to have an old Century mig welder and no matter what I tried the thing made me feel like an idiot. Nasty looking booger welds on thicker material and burn through on thinner stuff. Eventually moved up to a Miller 175 and a good auto-darkening helmet and all of the sudden I was a decent welder. Good equipment and being able to see what you are doing works wonders.

 

[ray66v]

I've been mig welding sheet metal in the auto body repair business for decades.

It's generally thinner than 14ga.

Many in my business like to use use .023 wire.

I actually prefer .030 wire. And, I can weld thin metal quite well with it. So, I can tell you it can be done.

.030 is generally called for in the factory service manuals, to make plug welds, when doing structural repairs.

I prefer not to use flux core, it is great if you have to weld outside in the wind. But, it splatters too much for me.

I use a Co2/argon mix. And, I like the welder set up a little hotter than most people.

It takes time to develop the skills to do it well. The more you do it, the better you should be.

 

[dragoneggs]

Good equipment and being able to see what you are doing works wonders.

Shield Arc taught me that! I tried his readers and it opened up a new world under my helmet! I since went to my LWS and got some cheaters that slide right into my helmet. Best improvement I made to my welds! Thanks again, SA!

 

[Big Barn]

Been running .030 exclusively with my 211MVP. I don't do so good with 14g or less, either. I guess I have to go through the hassle of swapping out wire to .023... or get a new welder!

Not a farfetched idea Mark. That's what I did.

.023 in the top machine
.035 in the bottom:



.045 dual shield in the Miller:

 

[dragoneggs]

Not a farfetched idea Mark. That's what I did.

.023 in the top machine
.035 in the bottom:

View attachment 546220

.045 dual shield in the Miller:

View attachment 546221

But then I need another cart! :laughing:

Old pic. I have a better flow meter now but I am embarrassed to say I have yet to paint the rack I added to a HF cart . :ashamed:



I guess maybe I'll start looking for a bargain. Probably could get away with a 110v only machine then with .023? The Miller cheat sheet on the inside cover shows 3/16in max recommended regardless of 110/220 for .023. I doubt I have tried anything thicker than 12g, maybe 10g with 110v. Not sure why I would need .023 for anything but thin gauge material so no need for 220v, right?

 

[Shield Arc]

Probably could get away with a 110v only machine then with .023?

I'm not big on 120-volt welders! I like power!:thumbsup: Take a look at the Everlast 140E Mig welder. A guy who lives in Tacoma came over for me to help him weld an extension on to a wheel barrow. He is going to convert it to a power wheel barrow. That is electrical conduit I welded around the top edge.

 

[flingwing1969]

Of course you can just get a portable tig/stick like I have. Just throw it in the back of the car and take it wherever you want. 450 lbs of love.