MIG wire breaking at the TIP

[Jay]

I'm another "FNG" to welding. I have a 220V MIG unit.

What am I likely doing wrong when the wire breaks off at the end of the tip and appears to be welded to the tip, as in I can't get the wire out?

TIA

[McClary]

im sure others will respond with more info ,

but i would say it be several different factors......


wire speed could be too slow , or the heat set too high, so when you stop welding, wire is burning up to the tip ....

other could be the gun too close to the work piece ......

but i would start with turning up the wire speed or turning down the heat ...

[geezer]

That problem can be caused by having a poor ground clamp, because a poor ground clamp will give you the impression your wire speed is too high as it pokes out more wire than you can burn, so you reduce the wire speed and sure enough the voltage burns the wire faster than it comes out fuzeing it to the tip. A GOOD ground clamp is an absolute must in mig welding. There are only two variables in mig, voltage and wire speed. without a good ground clamp you cannot dial it in properly. Get a good ground clamp real brass or use strands of copper wire attached to your existing one and see the difference.

[geezer]

One other thing I forgot to mention, keep your ground clamp as close as possible to the work.

Also because no two welders weld the same you could take a clean piece of 1/8 inch material practice dialing in on it until you get what you like then record your settings voltage wirespeed and stickout etc., this becomes you base point for to help solve future troubles. Most problems are ground clamp or wire feed tension, the ground clamp is always the most possible problem which leads to confusion on other settings.

[Ray]

One of the first things I did to my I-mig 200 was replace the ground clamp, need copper on the face.
One dead giveaway of a bad ground. if if you hear sounds like poping or a machine gun while your welding.
I found that you have to crank down on the tension more on these than I'm used to, slipping wire will act the same way, you can usualy hear the feeder motor change sounds when it slips.

[Jay]

Thanks Guys. I had read about cheap ground clamps so I coiled a thick copper wire around mine to increase the contact area before even starting. Though I will make sure I clamp closer to my work going forward.

I'm using the guide chart that came with the unit for determining voltage and wire feed speed based on material thickness, so that I'll at least be in the ball park. But based on your comments it sounds like I may be getting the tip too close.

I welded together a simple welding table top this afternoon. Photos were taken with a phone camera so I don't know if there is enough clarity and detail for anyone to comment on the results. But I'd sure listen if anyone does.

[performance]

Jay,

No offense, but those welds need some work. What gas and gas rate are you using?

What wire? There is too much spatter. That could be from too long of a stick out or too high of voltage. The arc should be stable and try the arc force about 3/4 of the way to the right. The sound should not be unlike a bumble bee or a mosquito like whine.

Move your gun to about 1/2 inch off the metal to weld right now.

A good point to start is probably about 18.5 volts with a wire speed a little over 200.

The wire speed feed is a relative number like 0 -10. Actually to convert to a close wire feed in inches per minute, multiply by 1.92 and will be close to ipm.

[Jay]

Jay,
No offense, but those welds need some work. What gas and gas rate are you using?
What wire? There is too much spatter. That could be from too long of a stick out or too high of voltage. The arc should be stable and try the arc force about 3/4 of the way to the right. The sound should not be unlike a bumble bee or a mosquito like whine. Move your gun to about 1/2 inch off the metal to weld right now. A good point to start is probably about 18.5 volts with a wire speed a little over 200.
The wire speed feed is a relative number like 0 -10. Actually to convert to a close wire feed in inches per minute, multiply by 1.92 and will be close to ipm.

No offense taken Mark. Other than watching some videos and maybe 30 - 45 minutes cumulative weld time I'm as green as they come.

I'm using a flux core mild steel wire .030". Voltage for the above welds was set at 18V and wire feed speed was at "4" on a 0 - 10 dial scale. The material thickness was 3/16".

Dumb question I'm sure but what did you mean by "try the arc force about 3/4 of the way to the right."? You mean how far I'm leaning the gun?