Mig Welding Contact
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MIG Welder problems?
Okay, so I have a welder that I've been using. Just replaced the wire, and now whenever I use the welder, the wire comes out at a normal rate.
But, for some odd reason, when the wire comes in contact with my welding surface, instead of a constant arc, it produces rapid arcs. I guess you could compare them to Black Cat fireworks. It just pops repeatedly. And It only started doing that after I changed the wire.
I have to admit that I released tension on the wire, and it spilled out a bit, but it didn't tangle. It still feeds normally and consistently. All my connections are as they were before. So what could be my problem?
Here is a PDF to the manual of the welder I am using, if that would help.
http://www.harborfreight.com/manuals/44000-44999/44567.PDF
I am going to run through a few things that might be the culprit, but a large truth is that it might just be the welder being cheap. Harbor Freight does not make good welders, and most of their stuff just does not last. The only power tool that I have ever been somewhat impressed by from them were some old angle grinders which kept on ticking, but a welder is a much different animal.
First, make sure that all the connections and parts are tight and the correct size. I have had problems in the past with tips that were silghtly loose or tips that wore down (both are probably not the problem though). Straighten out the house so there is less resistance for the wire and make sure the rollers are gripping the wire tight enough where you can't pull it out with a reasonable amount of force.
Second, check that all the settings on the machine are correct. With this welder it doesn't sound like there is much in the way of adjustment, but it seems that there is enough to work with for your needs. The wire speed is either too fast or you are running too cold i.e. the current is too low. I would max out the current and then fiddle with the wire speed. If you still can't get a decent arc at any speed then good chance the machine is shot.
If this is the case, pick up a Lincoln 100HD on ebay or find one locally. I picked one up online for $162 shipped with almost a fully 5lb spool of wire. There was one advertised here with wire and a gas setup including the tank for $200. Also, Miller and Hobart put out great smaller welders. They are much more reliable and better for you than any Harbor Freight welder. The frustration will be so much less if you start out with good equipment.
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