Mig welding experts

[Mission408]

Ever since my workers used my welder it pops like popcorn everytime I weld.
Hobart 140
Use .030 Hobart wire.
75/25 gas
Bottle @1700psi currently

I've probably put 20lbs of wire through this machine. Last winter we were a little slow so I paid our guys to work at my house and weld up a little addition to the garage. I let them use my welder. They used it with some extendion cords that were too small and I wonder if this could damage the welder?

They were 1 perlin short by the time work picked up and I welded the last one in. It was almost impossible to weld it was popping soo much. The guys using it I found out were dipping the end in bearing grease to keep the tip clean.

So I changed the tip. Tried several brands of wire. Blew through the gas hose and felt no obstructions. Set my gas to dip to 10 psi when welding. Traced my ground connections and all are good and tight. Grind,sand, clean my metal and no matter what I do it still pops. I can't run more than a 1/2" bead without a pop. It runs like crap.

Is it possible the electrical part of the machine is damaged?

(By the way I don't fault my workers, never told them. Just trying to figure this out)

[hoythunter]

I had a similar problem with mine and it turned out the handle & lead was bad. The inner liner gets damaged if its kinked at all (usually where it comes out of the front of the machine). The wire hangs up on it & doesn't come out smooth to make a weld. Bought a new one and it runs like new again.

[Filletem]

Run higher psi the lightest breeze will wash out 10 psi. Also check polarity if changed it will not weld for crap. Gas is one way flux core is the other.

[Mission408]

Thank you. I checked polarity. The wire to the naked eye comes out good but I might buy an entire new liner hose gun assembly and give that a go

[Dale Moser]

If the wire was exposed to much moisture, it could have surface rust on it, and that sucks.

They could have kinked the lead and ruined the liner.

Make sure the regulator is putting out gas. It can read whatever, but there are people in this world who turn off the line pressure on welders, and torches, when they are done.

Maybe they could have reversed polarity for flux core, I really don't know how that would react.

I am not an expert.

Draco should be along shortly to tell you exactly what is wrong.....and he'll be right.

[RifleBowPistol]

With either MIG or TIG, your shielding gas has to be around the arc when you are welding, or you get pop and splatter.

If you are getting popping splatter, it's probably a result of no shielding gas around the arc, or you are welding rusted metal, using rusted welding wire, or the metal you are welding has some form of contaminants in or on the metal you are welding. Basically the metal has to be rust free, paint free, grease free, oil free, the only thing that should be on the metal is the metal.

Basically forget about trying to weld outside or in a open shop with the doors open, if the wind is even slightly blowing. The breeze will blow your shielding gas away from the arc. I don't even have fans pointed at me, when welding with a TIG or MIG.

Then also, I typically have the flow meter set around 25 or up. If I am welding thicker metal, or have to welding with some breeze, I will turn the flow meter up to upwards of 35.

Setting the flow meter at 10, in a open building or outside, you are going to get nothing but splattering and popping.

Basically, probably not a thing wrong with your MIG, probably your welding conditions and adjustments.

Also, they do sell welding nozzle paste, I think it is some form of a wax, that you dip the welding nozzle in, when the nozzle is hot. It melts the stuff on the nozzle, to cut down on the nozzle getting slag or splatter in the nozzle. I have a tub of it, I bought 15 years ago, but rarely ever use it. I probably would not use regular grease for that purpose, it may cause problems with your welds. Likely as it gets hot, it would drip onto the metal you are welding and contaminate your welds. It won't hurt the MIG it's self.

[hog_down]

Dam n, that’s a tough one. Whenever you do figure it out, please let us know.

[Dale Moser]

I missed a part earlier. Sounds like you may have the wire speed too low for the heat.

[JustinJ]

So many things it could be. Gas pressure too low. Kinked liner in the gun. Wire speed too low/heat too high. Bad ground (if the purlin is red iron for sure).

I’d get two clean pieces of steel. Up your gas pressure. Set machine to recommended settings. Make sure lead is as straight as possible. See if you can lay a bead. Adjust from there before buying new parts.

[Big Lee]

Make sure the wire feed motor is up to speed. They can slip or get old and worn. Triple check your ground as well

[Mission408]

The open air red iron welding was a year ago. Since I've been welding completely indoors with no Breese and metal as clean as I can possibly get it. I'm ordering a new liner and will post results this weekend

[Draco]

Both mig and flux core machines are very sensitive to a good ground. I mean it has to be a very good ground so check that. As Dale said, even a slight dust rust on the wire can drive you crazy. Check your drive rolls to make sure they are gripping the wire good and not slipping. Be sure to check that ground though. Those little ground clamps that come with those machines are crap.

And a suggestion for you. Change that mix bottle in for a bottle of CO2. It will out last mix gas 10 to one and costs 1/4 as much as the mix gas. It makes for a hotter arc and gives you a lot more penetration, a big help for those little machines. You will need to change the nipple on your regulator though. Cheap to do and no big deal.

[Mission408]

Thank you Draco! I will check to make sure the wire is not slipping, and while I wait for my new hose/gun I will check into getting a co2 bottle. How do I go about finding what nipple I need for my regulator?

[hpdrifter]

Thank you Draco! I will check to make sure the wire is not slipping, and while I wait for my new hose/gun I will check into getting a co2 bottle. How do I go about finding what nipple I need for my regulator?

I would ask the welding supply personnel.

[tdwinklr]

With either MIG or TIG, your shielding gas has to be around the arc when you are welding, or you get pop and splatter.

If you are getting popping splatter, it's probably a result of no shielding gas around the arc, or you are welding rusted metal, using rusted welding wire, or the metal you are welding has some form of contaminants in or on the metal you are welding. Basically the metal has to be rust free, paint free, grease free, oil free, the only thing that should be on the metal is the metal.

Basically forget about trying to weld outside or in a open shop with the doors open, if the wind is even slightly blowing. The breeze will blow your shielding gas away from the arc. I don't even have fans pointed at me, when welding with a TIG or MIG.

Then also, I typically have the flow meter set around 25 or up. If I am welding thicker metal, or have to welding with some breeze, I will turn the flow meter up to upwards of 35.

Setting the flow meter at 10, in a open building or outside, you are going to get nothing but splattering and popping.

Basically, probably not a thing wrong with your MIG, probably your welding conditions and adjustments.

Also, they do sell welding nozzle paste, I think it is some form of a wax, that you dip the welding nozzle in, when the nozzle is hot. It melts the stuff on the nozzle, to cut down on the nozzle getting slag or splatter in the nozzle. I have a tub of it, I bought 15 years ago, but rarely ever use it. I probably would not use regular grease for that purpose, it may cause problems with your welds. Likely as it gets hot, it would drip onto the metal you are welding and contaminate your welds. It won't hurt the MIG it's self.

this is my recommendation as well. I would keep the 75/25 gas for standard steel welding. I never run the gas below 25 psi. Make sure your gas shield doesn't have any build up in it either, that will block your gas flow.
Make sure your machine settings are set close to the machine's chart recommendations or it will not run very well. Keep everything clean!
Good luck.