Need Help with Dual shield mig

[cbmkr]

We had the same problems for years with a particular brand of wire in 1/16" and 5/64" dia, The process that puts the flux in the wire was faulty. The wire started as a flat piece of material. As it was feed thru the forming process to make it a round wire the flux was deposited onto the partially formed wire. There problem was that the flux was not being distributed evenly causing air pockets and voids after forming it into a round product.The settling is what gave us the worm hole problem. The distributor of the wire we were using found the problem after opening up a section of wire and finding small voids in the powdered flux. At that time we changed brands and had no more such problems.

This was something that was a major concern to us ,as the welding process was for over the road and off road trailer chassis with GVW weight ratings to 80,000 pounds.

[SeanMurphy265]

Where I work we run.52 ( I believe) one step up from .45 Lincoln dual shield wire. I think it lays in flat and produces a nice looking weld. We run CO2 gas, I think 75/25 could be part of your problem. This is the wire I learned how to mig weld with. All of our welders whip it back and forth. When you get it set right it will run extremely smooth and have little to no splatter.