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Tool Talk Discussion Forum

Is it me? I'm Burning Tips

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Uncle

01-21-2006 14:49:30

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I don't know if it is just me or if I am doing something wrong.
I have a Miller 175 230VAC Mig and I am burning out tips after about 15-20 minutes of welding.
I am welding 3/16 plate, I am not using anything on the tips, .035 Flux Core.
The tips will get to where the wire will not feed through it smoothly and then it will kink and bind up in the tip.
I am willing to try anything.
Brian

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OK-AL

01-22-2006 19:40:02

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Re: Is it me? I'm Burning Tips in reply to Uncle, 01-21-2006 14:49:30

Do you have a tip made for .035 wire? There shouldn't be enough room in the tip for it to kink. It sounds like the tip you're using is made for larger wire.

Also, adjust the nozzle so that the tip is recessed inside the nozzle about 1/4". This setting works best for me.

What voltage and wire speed settings are you using? Flux core runs really fast compared to solid wire.

OK-AL

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OK-AL

01-22-2006 19:49:04

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P.S. in reply to OK-AL, 01-22-2006 19:40:02

Just had a thought. The smallest flux core wire diameter that i've every used is .045". If you're trying to push .045" wire through a .035" tip, then it's no surprise that it's sticking.

Also, the liner in the gun cable may need to be changed to a larger diameter.

Double-check your wire size.

OK-AL

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Stan in Oly, WA

01-22-2006 21:24:24

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Re: P.S. in reply to OK-AL, 01-22-2006 19:49:04

Good thinking. I thought I could prove you were right by looking through Lincoln's catalog of all the FC wire they sell (I guess it wouldn't actually prove it since someone else could sell a size wire that Lincoln didn't, but I'd consider it strong evidence.) Anyway, Lincoln sells just one type of FC wire in .035; everything else is .045 and up. But the one they sell is Innershield NR-211-MP, one of their most popular general purpose FC wires, so there's bound to be plenty of it around. That's not to say that Brian shouldn't check the match-up of the tip size to the wire size...only that it turns out not to be one of those great "Aha, problem solved," type situations.

Stan

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Alvin NE WI

01-22-2006 19:07:02

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Re: Is it me? I'm Burning Tips in reply to Uncle, 01-21-2006 14:49:30

one thing that i have used to clean tips are cutting torch tip cleaners of the right size. Also maybe the nozzle is shorting out, which should be cleaned of any spatter or the liner is dirty and the wire doesn't feed through good. One way to clean that is with blow air through it, or pouring paint tinner in to clean out and use air to blow through it out and dry..Are the drive wheels in good condition or enough or too much tension on them? Just my thoughts, some things I did when welding in industural job.
Alvin.

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Stan in Oly, WA

01-21-2006 20:13:52

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Re: Is it me? I'm Burning Tips in reply to Uncle, 01-21-2006 14:49:30

Hi, Brian

When I have a problem with something that hasn't been a problem before, the first thing I try to figure out is what's changed. Your question doesn't say whether you've always run .035 flux core and not had a problem with it, or if this the first time you've used it, or even if this is the first time you've used the welder.

I was running solid wire on a Lincoln machine this morning, not too hot and not too fast, and having the same problem you're describing. This is a machine that's never given me any trouble before. Nozzle gel/tip dip seemed to take care of it.

You've gotten good advice already, I don't have much to add. Making sure your polarity is right is the most important thing---nothing else will help if it isn't. You might pull off the contact tip and run a tip cleaner through the orifice. A little burr on that could cause your problem. Then use tip dip, and consider yourself lucky if you haven't bird nested your wire every time you burned up a tip.

Good luck, Stan

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Mr. Jeffries

01-21-2006 18:52:15

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Re: Is it me? I'm Burning Tips in reply to Uncle, 01-21-2006 14:49:30

Yeah, I'll second the use of a good nozzle tip...It'll keep things from building up on the tip and possibly keep the wire moving a little better...

Good luck,
Jared

Jasper FFA Homepage

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Lil-Farmer

01-21-2006 15:32:20

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Re: Is it me? I'm Burning Tips in reply to Uncle, 01-21-2006 14:49:30

Don't know about Miller, but on my Hobart 150 I have to change the polarity on the gun to run flux core wire. Can't remember whether it is DCEN or DCEP, but it is the opposite of running shielding gas.

Burnt up one gun because I didn't read the manual.

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01-21-2006 15:09:12

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Re: Is it me? I'm Burning Tips in reply to Uncle, 01-21-2006 14:49:30

Are you using any type of tip dip?

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01-21-2006 15:57:07

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Re: Is it me? I'm Burning Tips in reply to e, 01-21-2006 15:09:12

My Miller mig has to have the polarity reversed when using flux core. Miller and Hobart are owned by same company I'm told.

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Don-Wi

01-23-2006 06:15:58

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Re: Is it me? I'm Burning Tips in reply to HG, 01-21-2006 15:57:07

Miller is the parent company, headquarters is in Apppleton, Wisconsin(right next to Kaukauna, where I live). They manufacture under Miller of course, and also Hobart and Auto Arc. We've got an Auto Arc, and everything on it has miller either stamped or molded on it. Identicle to the Hobart ones at Fleet Farm.
Donovan from Wisconsin

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