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Old 03-10-2009, 12:41 PM
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Default Puddle gremlins...

They're alive in my welds and I can't figure out how to kill 'em.


The past few days I've noticed that my welds actually "grow" after I stop the weld. Usually I've seen it a little as it climbs up to the end of the wire and will leave a little peak as all the "coffee" comes to the top. That's no biggie, and I can deal with it. But what's happening now is unacceptable and I don't know where it's coming from. It looks like the puddle is actually bubbling/boiling afterwards. Sometimes it lays down, other times it climbs--as much as 1/2".

I've varied my gas input, cleaned all the materials well, and worked with speeds and temperatures. Nothing helps. When ground down, I've been expecting to find a pore or cavity left by the bubbling. Nothing is visible most times. Occasionally there will be a small pit, and on the biggest ones--there's a large bubble with a thin layer of filler around it. When I've cut the weld, it's solid between the base metals, no porosity or missed spots. The weld itself is good but extremely ugly because of the bubbled top layer.


Any ideas what's going on?
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Old 03-10-2009, 03:28 PM
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Have you checked your post gas time you could also check the gas flow at the torch nozzle with a flowmeter I never rely on gauges I set the gauges to what ever gets the flow at the nozzle I need
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Old 03-10-2009, 04:09 PM
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Possible problems:
Wrong gas
Bad or partially clogged gas diffuser
Bad post weld gas flow
Bad gas solenoid
Are you welding outside in the wind?
Are you holding the nozzle on top of the weld after letting go of the trigger to get full use of the post weld gas flow?
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  #4  
Old 03-10-2009, 04:47 PM
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Running flux core wire on a mig setup ?
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  #5  
Old 03-10-2009, 05:27 PM
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Could be the gas diffuser, I havn't checked it in a while. Might be good to clean it up.


The gas seems to be working fine, .035 solid, C25. I have noticed some intermittent "hot spots", where it acts like the machine runs out of gas for a bit but it straightens out pretty quick. I hold the nozzle down close to the puddle until it quits glowing through the mask, is that long enough?
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Old 03-10-2009, 06:24 PM
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Is the gun completely seated in the machine? If it has moved forward it might be partially blocking the Gas flow
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Old 03-11-2009, 12:09 AM
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Dirty wire?
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  #8  
Old 03-11-2009, 01:08 AM
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What brand and type of wire are you running? I have experienced similar problems using (lousy) firepower (napa brand) wire that went away when I switched to using hobart brand wire, same alloy (er70s6)
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Old 03-11-2009, 10:57 AM
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Could be dirty... it's been in the machine a while. I believe it's Radnor er70s6. The only lousy wire I've ever run through this machine was Lincoln...
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  #10  
Old 03-11-2009, 11:19 AM
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Dubby, you remember those birdshit welds I was getting out of my little Hobart on that shop stove I abandoned?
Last week I had to patch a mailbox stand for a tenant so I took the part home & fired up that 135 again for probably the first time in a year.

Same thing. It was so bad I thought I must have the polarity reversed. It was embarrasing.
Hell, it was so bad I ground it down and painted the joints!

The only thing I can come up with is bad wire or maybe the wire just won't weld with CO2.
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