MIG vs. Flux Core Welding

[CharlieTR]

I have had my little Lincoln 110V wire welder for over ten years now.
I use it on everything, just not that skilled at small stuff, does not seem to be a big need to weld thin steel on my little farm. I have only used Flux Core and never tried MIG. I want to build a big smoker and want the welds to look really good. Does MIG make better welds than Flux Core?

Thanks,
Charlie

 

[Transit]

Well, that's hard to say, too many variables. First, with MIG you will most likely be using er70s-6 wire and C25 gas. Depending on the thickness of the stock and how many amps your 110v unit can put out you are most likely limited to mild steel, 1/8 inch stock using 0.024 or 0.030, maybe 0.035 wires. Flux Core, that is Self Shielding Flux Core wire, starts at 0.030 in. At 110v you may be able to use 0.035 wires.
What this all means, is your unit powerful enough to weld the stock you have chosen to use. And of course the results are heavily dependent on your skill level. A pro can make a DIY machine tap dance.
Yes, MIG is cleaner than flux core if that is what your asking.

 

[sjames]

yes, mig makes better looking welds with less splatter than fcaw.

But you wont get the penetration with mig that you do with fcaw. Thats one of the reasons the 110v models are generally set up for flux core. And if your looking for appearance you probably don't want to run straight co2 either, which will further reduce your capacity.

If this is something you plan on towing, or moving around a lot, I would recommend you stick with the flux core for the heavier/structural elements of the smoker, and switch to mig for the rest.

 

[cdaigle430]

I have had my little Lincoln 110V wire welder for over ten years now.
I use it on everything, just not that skilled at small stuff, does not seem to be a big need to weld thin steel on my little farm. I have only used Flux Core and never tried MIG. I want to build a big smoker and want the welds to look really good. Does MIG make better welds than Flux Core?

Thanks,
Charlie

MIG is better for thinner metals and is more forgiving. The welds look better and you don't have to clean up the slag.

Flux core does have it's advantages, you don't need to lug around the gas, and it's better for thicker metals.

If you switch to MIG you will have to adjust your settings differently....

I personally preffer MIG because it makes my welds look better and cleaner.

 

[gauthier]

The welder is the one that makes the welds better,not the process

 

[Chilly807]

If you're wishing to have the gas set-up at the end of the day, it's as good a reason as any to get it. Typically you'll get better looking welds with gas shielding, although I've found that welding thicker metal, say 1/4 and thicker, that I get more spatter than I'd prefer using shielding gas.

For thinner metal found in a smoker, you will get good results using short weld bursts of 2 to 3 seconds, .023 wire would be my recommendation. Longer weld runs will tend to burn holes through the base metal in my experience.

Sean

 

[/pine]

...I want to build a big smoker and want the welds to look really good...

If you are welding outdoors and there is any wind at all shielding gas is almost impossible to use...

for a professional looking finish...
...make the best welds you can and clean them up (and the splatter) with some judicial grinding...then use a little body filler (Bondo etc.) to smooth out the rough spots...rub them out with some 100 grit and coat with a high quality heat resistant paint...

 

[redharley]

Sounds like you have plenty of time using your flux core and you would like to try somethiing else. If you jump up to a small 220 lincoln 30 amp mig set up which new is about $600 plus gas and tank[which don't come cheap] I think you will be happy.Take a little time to get the feel and your welds should look very good.I would hang onto that little flux core if you are use to the way it works for a while. also the wind factor if you do some farm repairs that are outside. Most migs can run flux core but some changes need to be made,sounds like that flux core has paid for itself no harm in keeping it if you like it. Good luck

 

[Window Geek]

Is body filler heat-resistant enough for a smoker? Just wondering...

 

[/pine]

Is body filler heat-resistant enough for a smoker? Just wondering...

...regular body filler is probably not the best suggestion...when I think "smoker" I think 250 degrees or less which polyester should tolerate...but a high heat epoxy filler is probably a better option...

 

[Transit]

Another point that was not covered, is your 110v mig only capable of using Flux Core or is it convertible?
You will need a solenoid controlled gas valve and the polarity must be changed, the +,- leads to the mig gun and clamp reversed.

 

[gauthier]

Well,I can weld[and make them look fairly good],1/8th thick stuff with a stick,,,if you got to spot weld 1/8th with a 110 volt mig,well....

 

[lostcause]

i use flux core for most things because i don't have to worry about being closed in the shop. if i were welding body panels, then that's another story. if you've been using flux core for a while then you should know your capabilities and appearance quality pretty well. mig will generally allow for less spatter to clean up and no flux coating to chip off. there are spray compounds that i've seen that are supposed to reduce spatter, but i don't know how good they work.

i'm not a welder by trade, but i've got a lot of time using flux core for various projects over the years, and in most cases with clean metal, i'm making welds that when under paint would be hard to tell the difference from mig. i do as much to diminish the appearance quality of the weld and metal when removing the slag with a needle scaler as anything else. i'm an ok welder and with my ability i think that mig will give a slightly better appearance, but it won't magically fix any mistakes made by the welder - it's mainly just less spatter and maybe a slightly smoother surface. if your welds are lumpy and irregular with flux, they'll be the same with mig, you just won't have the spatter and flux to contend with.

 

[CharlieTR]

Thanks all for the great replies!
I was not expecting too learn so much from my simple question.

Flux Core is all I have done and recently decided to spend more time welding.
I really like it and want to get more experience with other processes, and hoping the mig would smooth out the welds a little.

My little machine came with hose, gauge, other items to convert to mig gas. After reading this I might wait until I get a bigger machine. And after seeing Transit's reply, I don't like the idea of taking so much time to convert to gas.

Thanks again!!

 

[lostcause]

My little machine came with hose, gauge, other items to convert to mig gas. After reading this I might wait until I get a bigger machine. And after seeing Transit's reply, I don't like the idea of taking so much time to convert to gas.Thanks again!!

as long as your machine came with the hose and regulator to connect it to gas, then the change is pretty easy. i'm not sure with yours, bt with the two wire feeders i've owned, when you open the side of the machine where you load the spool and feed the wire you will see two heavy gauge wires on terminal posts. you swap the wires to change polarity when switching between gas and gasless.

that's always been one of my pet peeves with those machines. i imagine most people use one or the other, but i like to switch back and forth a lot depending on the task at hand. i'd be willing to spring for the $20-$50 when buying the machine to have them make it with a switch to change from dc- to dc+. the econotig i have includes a selector switch similar to this.

 

[Window Geek]

Got it! I was thinking "grill" and a smoker is definitely lower heat.

 

[Transit]

Charlie, dont let converting put you off. Many try to do things with there "Migs" that is beyond possibilities. You never said that your unit came with all the gas fix-ins. Flux Core only units are no more than a stick welder with a very long rod. However, installing the gas valve and regulator and changing polarity is a snap for a duel unit.
What are the units ratings, amps, duty cycle?

 

[Mark @ Everlast]

Transit,
Flux is NOT stick welding with a really long rod. I understand what you mean, but there are MAJOR differences. That's how rumors get started that end up being plain WRONG!

Flux core is a Constant Voltage machine. Without a voltage sensing circuit to constantly compensate wire feeding, you could not even thing of running flux core on Constant current. In wire feeding, the amps are actually controlled by the speed of the wire feeding into the puddle. Some Mig welders actually have an amp value instead of a wire feed speed, but they are essentially the same thing. In stick the voltage varies with the arc length, but current is fairly stable. Its just the opposite with wire feed systems.( I know this is oversimplification, but for a layman's understanding). Changing the length of the wire stickout varies the amps on wire feed systems and affects the burn off rate.

MIG and Flux core are the same type process, only MIG employs Argon, a regulator, and a solenoid circuit. FluxCore does not. Flux core has a flux in a small cavity inside the wire and as the wire melts the flux liquifies and the flux floats up to the top to shield the puddle from the oxidative effects of the atmosphere.

 

[yomax4]

MIG Welding or GMAW = Metal Inert Gas or Gas Metal Arc Welding.
Flux Core = FCAW or Flux Core Arc Welding. Two different processes. In FCAW you do not use gas and you should not have a whole lot of Slag but you will have a whole lot of Smoke covered welds and Spatter. There few variables in FCAW but dozens in Mig. In FCAW you run it how it runs best. In MIG, You have Short Arc, Spray Arc, Pulsed Arc and Twin Pulsed Arc. If you ever get to the later two, You will be in Welding Heaven..Until then, Arc and Spark till your hearts content.:thumbsup:

 

[DIXIEDOG]

Except for thin body panels and aluminum I prefer flux core, the anti spatter spray mentioned above will reduce the splatter some but it's not worth the cost in my experience. If I was tackling the job myself I would use the flux core, if your welds are good you can take a grinder to smooth them right up after and it will look great.:thumbsup: The gas will keep you from having to clean slag and it's a little easier to see without all the smoke but if you've got flux core down I wouldn't mess with the gas.