trying to set a old miller 250x using .035 solid wire. I am using the chart in the welding machine but cant seem to get the sound right or the bead profile I am looking for .welding on 1\4 inch angle iron that is 3 by 4 inches and 4 feet long. I am up to 392 ipm and 20.1 volts,this is the best sounding result I get but the weld looks kinda cold. when I increase the volts by like .6 volts the weld looks flatter but it starts to crackle so i know I am to high on the volts and I do see more spatter. the 392 ipm is what I set it at , the machine calls for 310 ipm and 19 volts on 1/4 mild steel,but the weld looks cold and does not sound right at all for 1/4 steel ,these setting are also for 75 argon and 25co2. I got a 3/8 stickout as well. not sure if these results are common with this gas and short circuit. I measured the wfs with a stop watch and measuring tape and realized the digital readout is off too but did correct it before trying these settings. any input would be
greatly appreciated.
Try holding WFS where it is and increasing voltage incrimentaly. The CO2 is the special sauce for short circuit. Reducing it could call for some more "uhmfh". Also, angle has one of the most tenacious mill scale's of all the hot rolled. Thick mill scale will definitely cause sputtering in short circuit. Try grinding it clean.
Let us know how it goes.
BV
I’m gonna try it out some time this week. I think you’re right about the mill scale. It was sitting outside on a rack over the winter, I grinded it down but there was still some pits in it from the rust corrosion. I got it down to the point where it was shiny but not quite smooth. When you say “umfh” you mean more volts. Does more argon in the co2 mix require less volts, I read that when you go from straight co2 to using 75 /25 gas you would go down a 1 volt or 2. I was wondering if going to 85 /15 gas you would maybe reduce another 0.5 volts or so,when I do this the sound is more consistent but the bead profile is a bit higher not as flat as I think it should be.