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Unread 11-14-2008, 07:45 PM   #1
firejeep344
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Base metal temp affecting welds????

Hey guys I was welding tonight and the welds were very porous. It was almost like I had a lot of rust or oil in the weld, but it was clean bare metal. I am welding 1/8" box with a hobart 187 at 5/50 with 25/75 gas nad .030 wire. It got down to like 25 degrees. Welds were great yesterday @ 60 degrees and nothing else changed. Would a lack of gas be doing the same thing? I have like 550 psi left in the bottle and the flow is @ 30 -35 lpm. I also thought my nozzle may be clogged. Any tips and help would be appreciated.

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Unread 11-14-2008, 08:33 PM   #2
Bear-Olemiss
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Take a torch an preheat just a touch, to get the chill out. Yes. base metal temp affects welds and BTW gas is too high.. 22-25 lbs
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Unread 11-15-2008, 12:26 AM   #3
mcneil
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The torch will also burn off any excess moisture, which causes porosity.
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Unread 11-15-2008, 01:56 AM   #4
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check your O-rings on the gun lead. my friend and I screwed around for two weekends trying to figure out why we had porosity...turned out the O-rings where shot. Replaced them & applied a light coat of vasoline and they welds were perfect again.
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Unread 11-16-2008, 05:21 AM   #5
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Quote:
Originally Posted by firejeep344 View Post
Hey guys I was welding tonight and the welds were very porous. It was almost like I had a lot of rust or oil in the weld, but it was clean bare metal. I am welding 1/8" box with a hobart 187 at 5/50 with 25/75 gas nad .030 wire. It got down to like 25 degrees. Welds were great yesterday @ 60 degrees and nothing else changed. Would a lack of gas be doing the same thing? I have like 550 psi left in the bottle and the flow is @ 30 -35 lpm. I also thought my nozzle may be clogged. Any tips and help would be appreciated.
I doubt the base metal temp being 40 degrees cooler would affect the weld considering the thousands of degrees temps created by the arc. Welding mild steel takes place in the coldest of climates without preheating. Your nozzle could need cleaned. Also, you state your gas flow in l/min? You have a funky regulator/flowmeter on that bottle. If it's the one that comes with the 187 it's in cf/h increments, not l/min. One last thing, I think tap 5 might be a bit hot for 1/8" and on tap 5, the wirespeed of 50 i/min would be on the low side. Give tap 4 a try with the wirespeed at 50-55.

Sorry, I have to keep typing here. LOL 550 psi left in the tank is still plenty of gas. That's not your problem. Was there any breeze blowing where you were welding?
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Unread 11-16-2008, 06:07 AM   #6
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I would check a few things first. If your connection of the gun to the machine is like mine, it is very possible that you are not fully seated into the bracket allowing gas to leak out past the o rings. You could have a gas leak at the back of the machine or the tank.
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Unread 11-16-2008, 08:58 AM   #7
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If the metal is pretty clean, the next place I'd look is at "lack of shielding gas" as mentioned already. As for the 550psi, that's plenty. I alwasy run my bottle till it doesn't even register on the PSI gauge. Then, I keep my eye on the flow gauge until it drops to about 20ish... or slightly below. When it won't maintain 20cfh, I switch tanks.
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Unread 11-16-2008, 10:44 PM   #8
firejeep344
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Thanks for all the help. I think that it was a clogged nozzle. I cleaned it out and everything seemed ok. I just did a few spot weld though no long beads. I was mistaken about the lpm (thinking of O2 at work) it is cfh, and I turned it down to 25. That should help a tank of gas last longer eh. We'll see how it goes tomorrow when I finish my fenders.
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Unread 11-17-2008, 02:37 PM   #9
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I actually have trouble with my welder below about 40 degrees. The wire will not spool out smoothly and instead it come out jerky. Instead of getting the “frying bacon” sound, it more like someone playing a bass line through a blow speaker.

I can sit there and watch the wire slipping on the drive wheel, but it will not improve no matter how much or little tension I have on the drive wheel.

Any suggestions?
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Unread 11-17-2008, 03:03 PM   #10
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Originally Posted by E_ROCK View Post
I actually have trouble with my welder below about 40 degrees. The wire will not spool out smoothly and instead it come out jerky. Instead of getting the “frying bacon” sound, it more like someone playing a bass line through a blow speaker.

I can sit there and watch the wire slipping on the drive wheel, but it will not improve no matter how much or little tension I have on the drive wheel.

Any suggestions?
point a small heater at the welding wire? not enough to cause the welder to overheat and shut off, but just enough to raise the temp around the welder to ~50.
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Unread 11-17-2008, 07:02 PM   #11
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I've run my welder (Miller 210) in temps below freezing without problems. Maybe your liner needs to be changed out?
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Unread 11-18-2008, 05:24 PM   #12
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Originally Posted by BESRK View Post
I've run my welder (Miller 210) in temps below freezing without problems. Maybe your liner needs to be changed out?
Maybe, I have only put like 25lb of wire through it. What is the recommend amount of wire to feed though it before changing it?
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Unread 11-18-2008, 07:55 PM   #13
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I would get porosity in my welds occasionally. I tracked it down to the wire i used had corrosion or contamination on intermittent spots towards the end of the roll of wire. What a pain in the a**. I had to strip off a bunch wire and look at it in good light to find it. Name brand wire, pi**ed me off.
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Unread 11-18-2008, 08:01 PM   #14
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This is why I prefer TIG welding.
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Unread 11-18-2008, 08:59 PM   #15
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Maybe, I have only put like 25lb of wire through it. What is the recommend amount of wire to feed though it before changing it?
i think its about how the material deteriorates over time and use in that time...i.e. sunlight (UV rays) break down plastics, rubber dries out and cracks, steel rusts, etc. How much gas you cycle through will probably effect it too...Argon being very inert will probably make the liner last longer, but flux-core & air will probably deteriorate the liner faster. I'm sure rusty wire would scrap and causes deterioration as well. I don't know crap about liners tho, haven't had to replace one yet...

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