120v MIG weld on a 3/8" thick (bevel 60deg)

[FTG-05]

Having suffered thru all the insulting mud slinging of this thread and why 110V may not be for everybody, this one item pretty much sums it up "2-3 hours for 6-8" of weld is pretty time consuming".
This is what happens with my little Lincoln 110v MIG. The duty cycle prohibits using it on high range for more than a few seconds so it sets in storage and I just stick everything. I don't have time to wait 5 minutes ever 15 to 30 seconds for a cool down cycle. I cant believe that other's machines don't have a thermal overload protection device on them or that they can weld forever with them and not shut down for cool off.
I don't doubt that you could weld up 2"+ thick material with a 110 V MIG if you are young, and wealthy so you had many, many hours of free time to invest, but I am not in any of those categories so I wont be using my 110v MIG for welding. If I ever bought another on it would be 220V and minimum 250 amp rating with 60% duty cycle minimum.

Having made my thoughts know, I wont be back to this thread.

I've welded 2" thick steel with my 240 vac welder although it was nothing more than a test of machine's ability to weld flat out before it temp-tripped.

I took some 2" plate and made a 145 lb anvil and welded it up at a local welding shop using some huge stick welder. I think I was using 1/4" (maybe bigger? don't recall) to make all the real welds. I did it under the guidance of the owner; for what it was going to be used for (banging crap together) it worked just fine.

Then when I got it home, I started on it with my Lincoln SP-175 Plus just to see how long it would take before it shut itself off. I ran it with .035 wire, with the heat all the way up and the wire speed about at the 75% point. Welded for about 5-6 minutes before it started sputtering then finally shutting off. Let it cool 15-20 minutes and started right up again. By doing this, I'm now able to tell when the machine is starting to overheat and can back off or stop and let it cool before it shuts down due to overheating.

All of which has nothing to do with using a 120 vac welder, so sorry for the thread drift.

Back to 120 vac welder tips and tricks.....

Thanks,

 

[Fifelaker]

I believe you said you where using flux core. I guess i am asking to much, but have you considered 75/25 argon or plain CO2. CO2 would help with the penetration. I have only read about using tri mixes with helium, with that said, I have read the helium would allow a hotter weld with lower amperage and might just be the ticket for those folks that dont own a 220v machine, yet still need to join heavier material than their machine is normally rate for. Again, I have no experience using trimix with mig.

Flux core is hotter than C25 (75/25). I have C25. I have know that pure co2 is hotter but I do not think it is as hot as flux core. Have you priced helium lately? It would not take too long to pay for more amps. Last I knew helium was $160 for a 40 cu/ft. cylinder, I pay $38 for a 125 cu/ft. of C25. There is a shortage and it commands premium dollars. This is on the back burner for a couple of days as I have paying job that needs to be done by Sat. I will have results and pics by next Tue.

 

[Fifelaker]

Depending on ambient temps duty cycle is different. You will weld longer at 30° than you will at 90° before it trips, it will also cool down quicker. Most ratings have a temperature that they are tested and rated for. The higher the rating the longer you can weld when it is cooler.

 

[muddstopper]

I may be wrong on this, but I believe flux core runs hotter than solid wire because there isnt as much metal in the wire. It might be the same dia, but flux core is hollow wire with flux in the core. Less wire, less fillment. I suspect more penetration could be achieved by simply downsizing wire size and switching to CO2. I dont know this, just guessing. Willing to listen to a pros thoughts on this.

Never said Helium was cheap and suspect the price of helium is why most folks now use argon.

 

[Fifelaker]

I also believe the flux add some heat when it burns. In me experience .035" FC is hotter than .023" with C25. I can weld thinner steel with the thinner wire w/gas than I can with flux core. I have had to do the trigger thing with FC where I can keep the trigger pulled and weld with the wire and gas. I keep cardboard and tent building stuff with me anymore when I will be welding where the wind may blow the shielding gas away. Tarps, cardboard and tape can be your best friend. I did a lawnmower deck for a friend awhile back that amazed him how much difference a piece of cardboard made.

 

[firemanmike69]

I am doing my best to give some down to earth info.

If I understand correctly you are running wide woven beads ? Might be better off to run stringers till the cap then weave so you don't have so many starts and stops in the areas you're going to be bend testing, I always try to get my starts and stops out of the bent area, even if it means throwing away most of a rod. What about preheating in a toaster oven, no propane to use and you can weld, pop it in the toaster walk away while the welder cools down and pop it out and weld again when you/welder are ready. Try blowing the vents of your welder out dust and crap can accumulate in there and hinder cooling

 

[kcender]

As a matter of interest the title of this thread indicates it is dealing with MIG welding.My understanding is that MIG is a common term used for welding with a wire feed machine using solid wire.The proper terminology is GMAW or gas metal arc welding.When a flux cored wire is used it is no longer MIG welding but FCAW or flux core arc welding.Some members may find this nitpicking but some members are saying they want to learn.Maybe some will find this interesting.

 

[muddstopper]

As a matter of interest the title of this thread indicates it is dealing with MIG welding.My understanding is that MIG is a common term used for welding with a wire feed machine using solid wire.The proper terminology is GMAW or gas metal arc welding.When a flux cored wire is used it is no longer MIG welding but FCAW or flux core arc welding.Some members may find this nitpicking but some members are saying they want to learn.Maybe some will find this interesting.

I think most folks use the FCAW and GMAW as interchangeable terms, even tho it isnt technically correct. Both methods use wire, its a difference in shielding methods. And then you have dual shield

GMAW vs FCAW-S Process

 

[kcender]

I think most folks use the FCAW and GMAW as interchangeable terms, even tho it isnt technically correct. Both methods use wire, its a difference in shielding methods. And then you have dual shield

GMAW vs FCAW-S Process

Agreed that most people use the terms interchangeably.Disregarding the self-shielding wire method the only real difference is the type of wire used.The shielding gas may,or may not,be the same.It is really a small point but when I hear,or say,MIG welding I immediately think of welding with a solid wire.

 

[MinnesotaDaveChalmers]

Agreed that most people use the terms interchangeably.Disregarding the self-shielding wire method the only real difference is the type of wire used.The shielding gas may,or may not,be the same.It is really a small point but when I hear,or say,MIG welding I immediately think of welding with a solid wire.

Hey don't forget MAG - metal active gas