Using a cheap flux-core welder....

[Jim Saraceno]

Harbor Freight just had a 90 amp flux core welder on sale for $100. I'm aware this is a very low end welder with a short weld cycle and I realize that a mig would make a much nicer weld; but I very seldom ever need to weld and I just can't justify the extra cost for something nicer.

My question is about the amount of splatter. I'm very happy with the bead it lays down but and surprised at the amount of splatter left when I'm done.

Is that just the nature of the beast or is there some technique that I can use to minimize the splatter?

[55 Fargo]

The nature of Flux Core, is there any anti-splatter you can try. I also would try good quality flux core wire.

I just use the wire brush attachment, to clean up weld areas with flux core, it generally works well and cleans up nicely.

Flux core, will never be as neat and tidy as mig , where there is gas, and a much finer wire.

[rustyzman]

Though it does not help the spatter on the surface you are welding, hitting the inside of the nozzle, removed from the welder, with some cooking spray will help prevent build up and eventual bridging of spatter inside the nozzle. The spatter on the workpiece though is inevitable with flux core. A wire brush on a die grinder or an angle grinder will be your friend both before and after the welding is done.

[Jim Saraceno]

Thanks for the tips. I think one of my problems is I had the nozzle to far away from the metal.

It's getting better. It has been 20 years since I had a welder in my hands and that was an arc welder. I need more practice for sure!

[rustyzman]

Welding is like riding a bike, you never forget it. Besides, if you know how to stick weld, MIG is a piece of cake. Plus you already know about the prep and cleanup. A big plus is no slag to chip! (though I still prefer arc welding on heavier metal)

[greg g]

Hey you welder types. When using a wire welder, whats the prefered direction?

tip toward the work or toward the bead???

[Dodgeb4ya]

I Push for shallow penetration / pull (wire aimed at bead) for deeper penetration-heavier metals.

I run an XMT304. High end Miller inverter machine.

Edited March 13, 2011 by Dodgeb4ya

[louie the fly]

Hey you welder types. When using a wire welder, whats the prefered direction?

tip toward the work or toward the bead???

Greg, I was always taught "if it makes slag you drag", meaning you pull the weld. With MIG (gas) you push the weld. I normally have my torch perpendicular to the weld plane and leaning back around 15 - 20°. This helps clear the spatter so it doesn't build up too quickly in the nozzle. Spray the tip and the inside of the nozzle with anti spatter every time you clean it. I do a lot of robotic MIG setting and you can get away with various torch angles and still get excellent results, so angles aren't THAT critical really.

The most important thing I tell apprentices is know your equipment and what it's capable of.

Louie

[Tim Keith]

You might improve the duty cycle by installing a larger cooling fan

[Jim Saraceno]

Spray the tip and the inside of the nozzle with anti spatter every time you clean it.

I never heard of such a thing. I assume it is something I can buy where I bought the welder?

BTW, according to the instructions that came with the welder, you point the tip toward the bead at a 15 deg angle.

[rustyzman]

Yes, anti-spatter spray is available at welding supply houses. For me, cooking spray is cheaper and works fine. Just a matter of preference.