Welding wire size

[Z06killinsbf]

Is there much to be gained by going from a .035 wire to a .030 size? I'm having problems of blowing holes through sheet metal just tacking it. This is flux core btw.

[turbostang]

Smaller wire would help some, but flux core is the root of your problems.

[Sean88gt]

What is the rest of your setup? You may be running too hot, speed too fast, shitty gas, and shitty wire.

[Z06killinsbf]

What is the rest of your setup? You may be running too hot, speed too fast, shitty gas, and shitty wire.

I don't know much about the welder as it is a dinosaur. I'm running .035 flux, coldest setting, speed at about 40.

One thing, I was freshening up on thick steel and it would go good for about an inch or more burning good with a steady flow and then start popping and splattering. Is that the welder being a POS or am I too close/far?

I've welded a lot in the past but nothing in about 6 years.

[Sean88gt]

Has the liner ever been changed? Is your tip burnt?

[Z06killinsbf]

I doubt it, no on tip. Everything is clean.

[TexasT]

You might even move down to an .023
If you can, go to a 75%ar/25%cd mix shielding gas with a shielded wire. This will cut way down on all the spatter.

[Blackpony]

He is running a flux core. I would suggest speeding up your wire feed. I typically weld at a 6 depending on the thickness. Sounds like your filler isn't coming in fast enough to fill the gap as it heats up.

[TexasT]

He is running a flux core. I would suggest speeding up your wire feed. I typically weld at a 6 depending on the thickness. Sounds like your filler isn't coming in fast enough to fill the gap as it heats up.

I got that he is using flux core, that is why I included "if you can" when suggesting moving to gas shielding. He might even try an 80/20 mix of ar/co2 to further cool the weld and prevent burning holes.

Flux core is cheap and good for outdoor and windy places but leaves much to be desired for producing "quality" welds.