Bad Welding Wire?

[RockMonkey]

Anyone have experience with bad welding wire? I ran out of wire yesterday. All my welds have been looking good recently. I swapped to a new spool of wire, and instantly my welds are getting swiss-cheesy. Just exactly like I'm out of gas, except I'm not, and it happened exactly at the same time I switched the wire. Any ideas? I hate to throw away a brand-new spool of wire...

 

[Herzog]

I've had issues with old wire that's been sitting in my welder for a long time. Swapped in a new spool and had instant awesome weld-ability.

Could be a bad spool. Maybe take it back?

 

[BCGPER]

Where did the wire come from?

NEVER buy wire from Harbor Freight! What's the wire number, you may have just been slipped the wrong wire by mistake. Also, what gas are you using, and would the breeze be an issue (if you're working outdoors)? Yes, some wires are better than others.

 

[Caleb]

Where'd you get the wire? I have had bad spools. Usually they are either from one of the improvement stores, or they have been sitting around for a while. The wire will oxidize and cause what you are seeing. You can try to return it if it's not too old or you can pull a ton of wire off and see if it gets better. I've had it get better once you get through the first couple layers of oxidized wire, I've also had it not get better.

 

[I Lean]

I've had wire weld better or worse, but never "bad".

Do you have any other wire you can try, just as a test? (I keep a 2lb spool for when I run out, that I would try--or you could borrow and try)

 

[RockMonkey]

I'm pretty sure this came from Airgas. It's P3 brand. ER70S-6 .030. It's probably a year old or so, and was in a box, and the spool itself was wrapped in plastic and paper inside the box.

The old spool, that was welding awesome, was Lincoln Electric SuperArc L-56, which is also ER70S-6 .030.

 

[RockMonkey]

I've had wire weld better or worse, but never "bad".

Do you have any other wire you can try, just as a test? (I keep a 2lb spool for when I run out, that I would try--or you could borrow and try)

The only other wire I have is flux-core.

Oh, to answer BC's question, all the welding has been in the garage. I'm using C25 gas. Wind hasn't been an issue. I did try to turn up the gas a bit, and verified that the gas was actually coming out the tip. I also tried turning up and down both the power lever and wire speed.

 

[UNSTUCK]

Run your fingers down the wire and see what kind of residue you pick up. I've been using the cleaner pads and lube pads by Weld-Aide and have been very happy with them. They wrap around the wire between the spool and drive wheels. I also keep a small bucket of desicant in there to suck up any moisture.

 

[lewis]

I had a similar problem 2 weeks ago. My welder is a MM 180. I got to looking at my welder and the tube that holds the gas in the gun had cracked just as it went into the welder. I peeled back the outer cover and discovered it. I also couldn't feel the gas coming out the end but could still hear it. Something to look for anyways.

 

[RockMonkey]

Run your fingers down the wire and see what kind of residue you pick up. I've been using the cleaner pads and lube pads by Weld-Aide and have been very happy with them. They wrap around the wire between the spool and drive wheels. I also keep a small bucket of desicant in there to suck up any moisture.

I ran a clean white cloth over the spool, and picked up a bit of black residue. It wasn't a lot, but I don't know how much is too much.

I had a similar problem 2 weeks ago. My welder is a MM 180. I got to looking at my welder and the tube that holds the gas in the gun had cracked just as it went into the welder. I peeled back the outer cover and discovered it. I also couldn't feel the gas coming out the end but could still hear it. Something to look for anyways.

I could feel the gas coming out the tip of the gun on my cheek. It felt normal. I really don't think the problem has anything to do with the gas.

 

[Milner]

I have had a bad spool before. It was very frustrating. Switch it and I was back to normal....Never buy wire at NPS

 

[zukijames]

I bought some flux core from cal ranch when I first was learning to weld. I thought I just couldn't weld so I gave up. I couldn't get a puddle just make a mess. Friend came over he couldn't get it to work either. I bought a new spool and now I love welding.

 

[waynehartwig]

Sounds like you got a bad roll of wire. It happens. See if they will take it back?

As for the wire cleaner, I use a simple process. I take some red scotch pad and fold it in half over the wire. Then I take one of those black springy paper clips and clip it to the wire. It will take anything off the wire Then store all of your wire in the fridge - it will protect it from moisture.

I buy all of my wire from Enco. Cheaper and have yet to have a bad roll. I think the last 33# roll I bought (last month) was ~$45? I buy several at a time. They will also send out coupon codes for % off and/or free shipping. The 3 rolls they sent me last month were on their dime
here:
http://www.use-enco.com/CGI/INLMK32?PARTPG=INSRAR2

 

[DOSS]

Sounds like you got a bad roll of wire. It happens. See if they will take it back?

As for the wire cleaner, I use a simple process. I take some red scotch pad and fold it in half over the wire. Then I take one of those black springy paper clips and clip it to the wire. It will take anything off the wire Then store all of your wire in the fridge - it will protect it from moisture.

I buy all of my wire from Enco. Cheaper and have yet to have a bad roll. I think the last 33# roll I bought (last month) was ~$45? I buy several at a time. They will also send out coupon codes for % off and/or free shipping. The 3 rolls they sent me last month were on their dime
here:
http://www.use-enco.com/CGI/INLMK32?PARTPG=INSRAR2

Scotch brite pad and the clippy is what I use too.. works great (just remember to clean/change it with every new roll you put on..
I store my wire in the freezer (the wife got mad at me using the crisper drawer in the fridge)

 

[waynehartwig]

Scotch brite pad and the clippy is what I use too.. works great (just remember to clean/change it with every new roll you put on..
I store my wire in the freezer (the wife got mad at me using the crisper drawer in the fridge)

It's amazing how much crap comes off even a good roll of wire...

 

[utah340six]

make sure the cord is pushed back into the welder all the way before you titen the bolt.
because if thats not back in all the way no gas.
same problem.
you are using same size of wire?

 

[RockMonkey]

make sure the cord is pushed back into the welder all the way before you titen the bolt.
because if thats not back in all the way no gas.
same problem.
you are using same size of wire?

Same size of wire. I can hear and feel plenty of gas coming out the tip, so gas delivery is not the issue.

 

[I Lean]

Come get my spool of wire and try it, just to confirm or eliminate the wire as the culprit.

 

[RockMonkey]

Come get my spool of wire and try it, just to confirm or eliminate the wire as the culprit.

.030 ER70S6? 10-12 pound spool?

 

[I Lean]

.030 ER70S6? 10-12 pound spool?

Affirmative. Although it's somewhat less than 10 lbs now, since it isn't new....