Blue Demon flux core wire?

[California]

I doubt I'll ever go to gas. Where I can, I like to keep things simple. Gas would add cost, transport, storage space. Welds would be prettier but not likely stronger, which is my only objective.

My shop is open-air so gas might not be much of an improvement.

Cleanup of flux splatter with wire wheel or flap disc, maybe even grinding, is sufficient for what I do. My present project is modify an old back blade so the q-hitch can pick it up. Nobody will care about evidence showing that that splatter was removed.

 

[5030]

My shop is open-air so gas might not be much of an improvement.

It won't be. in fact it might be detrimental unless you really crank up the pressure and then all you do is waste shielding gas.

 

[cqaigy2]

I doubt I'll ever go to gas. Where I can, I like to keep things simple. Gas would add cost, transport, storage space. Welds would be prettier but not likely stronger, which is my only objective.

My shop is open-air so gas might not be much of an improvement.

Cleanup of flux splatter with wire wheel or flap disc, maybe even grinding, is sufficient for what I do. My present project is modify an old back blade so the q-hitch can pick it up. Nobody will care about evidence showing that that splatter was removed.

View attachment 693647

I'm kinda in the same spot, open air welding just outside the shop. Plus most of my past welding was stick so flux cleaning is second nature, and now i weld so rarely, not really economical for me to add gas to the mix. Not saying i wouldn't use gas if i had it, but not going to setup for it.

 

[ning]

I'm kinda in the same spot, open air welding just outside the shop. Plus most of my past welding was stick so flux cleaning is second nature, and now i weld so rarely, not really economical for me to add gas to the mix. Not saying i wouldn't use gas if i had it, but not going to setup for it.

same here; my results are better than I'd expect already being an untrained occasional welder, work mostly outside, so... why change haha

 

[yomax4]

TGS wire is the worst of the worst. If FC is what you need for your project it's always better to spend an extra dollar for -11. No-one wants to be wasteful but I suggest throwing all of the TGS in the garbage.

 

[California]

I think this Blue Demon wire stalls because it really is snarled up on the spool, as I saw in some Amazon reviews. That's why I'm thinking about spooling some wire off to see if it will feed better from the other spool.

... And that really was the problem. The Amazon reviews said some spools of Blue Demon won't feed smoothly. This is what I experienced. I had heard the feed motor slow and stall, frequently, where I had to pull the wire out of the tip with pliers.

I cut the wire near the spool, mounted an empty spool on my drill, and tried to pull wire onto the external spool. There were several moments with so much resistance that I nearly dropped the drill. I could see 'elbows' in the wire as it fed toward the second spool, and saw one crushed spot that never would have gone through the welder tip.

I'm pretty sure I never let the wire 'rats nest' mounting it originally or during this spooling.

At 5030's suggestion I replaced the Blue Demon flux wire with INE. Problem solved. The wire feed motor now runs at a smooth hum in contrast to the uneven speed before. And the weld bead is continuous. Problem solved.

 

[5030]

I really like INE, buy it in multiple spools. I could be mistaken but (I think), not 100% sure, that the HF wire is also INE. Spools look identical labelling is not. I'll let that lay until someone confirms it.

 

[Ddh1961]

I really like INE, buy it in multiple spools. I could be mistaken but (I think), not 100% sure, that the HF wire is also INE. Spools look identical labelling is not. I'll let that lay until someone confirms it.

Both the INE and Vulcan (HF) wires are made in Italy so they could be from the same manufacturer, but I cannot confirm this. I’ve used both and prefer the INE as it seems to have a little less spatter, but that’s just on my machine. I use INE exclusively and keep a roll of the Vulcan wire in reserve in case I run out in the middle of a project.

 

[JPinnell]

AMZ has the Hobart E71T-11 .035 for $60/10lb spool which is about as cheap as anywhere. I've tried the BlueDemon, other off brands, and even the HTP (which is supposed to be USA Made) and they all have issues at times, just not consistent. I used LOTS of the HTP with no issues, then fought 4 spools of crap. I even upgraded my 8+yr old HH210 for feed issues (think the feed motor is worn, multiple liners) to an IronMan 230 I was so frustrated. The IM230 is nicer, much more robust feed rollers, but it hates cheap wire too. Now the HH210 is a portable spare and I'm only running the Hobart E71T-11 or maybe good Italian wire. $25 difference on cheap vs quality 10lb spool, not worth the hassle and frustration.

I will also say the FluxCore wire will not feed as nicely as solid wire, just the nature of the beast. Too much roll pressure will flatten the wire and make things worse. There is definitely a sweet spot.

 

[yomax4]

As stated above. There is a night and day difference in gasless cored wires. Please check to see what you are buying. 70TGS is the worst of the worst in welding wire no matter the brand and it's a single pass dirty wire.. For a buck more you can get the gasless 70T-11. It is the best of the worst and it's designed for multi-pass welding. Once compared on your table anyone would agree that the extra buck is well spent. So if anyone has to go gasless, Consider T-11 and don't look back.