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MIG Welding (FCAW) arc start issue

3728 Views 11 Replies 7 Participants Last post by  CattleRustler
for those of you who have MIG welded using FCAW or FCAW and GMAW I have a question for you:

in FCAW
have you ever seen where, when starting the arc, the first 1/2" of wire glows orange and breaks off and falls into the seem, then the actual good arc starts?

this may be an fcaw-only issue (as opposed to gmaw) but I was curious if that happens sometimes in gmaw as well.

my hunch:
I am going to try clipping a little bit of wire off before each weld because I think it may be related the wire tip being contaminated from the previous weld (flux core soot, etc) and not making good intitial contact on the next weld start, but I was doing that a bit yesterday and I was still seeing this thing happen.

any insights from resident welders?
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I've done some GMAW (MIG) welding (may have been MIG with flux-cored wire) in the past and from experience the length of the wire from the tip of the "torch" is very important. If the wire length coming from the torch is too long then it's hard to strike an arc, though if it's too short then you can weld the wire to the tip of the torch. Around 1/4" from the end of the wire to the torch tip works very well. Also, unless the wire extending from the tip of the torch is too long, it's not necessary to clip off the end of the wire.

FYI, for wire feed welding it's best to keep the torch tip close to the weld (again ~1/4" or so) as this produces better welds and less splatter.

Edit: the reason why the wire length is so important is that the tip of the torch is the contact that supplies power to the consumable electrode (wire) so added wire length means more resistance and less current to strike the arc. Further, when doing MIG welding (or FCAW with a shield gas), when the wire is too long the end will be outside the envelope of the shield gas, which results in poor welds.
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thanks Rado, I know and understand all that, and while thats a great bit of information for anyone else reading this (as always) it doesnt really apply to my specific question, which I think may be stictly an fcaw-self shielding wire phenomenon, but not sure. Thanks tho.
Try increasing the voltage a little.
It sounds like a cold start.

Gyro
Quote:

Originally Posted by Gyro View Post
Try increasing the voltage a little.
It sounds like a cold start.

Gyro
Classic overclock.net approach to problem solving: More voltage!
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correct tip diameter ?

iirc , the flux core wire requires a reversal of the machines polarity , but i guess that depends on the machine .

( oh btw , personally i strongly dislike flux core wire. spatterriffic !!! )
thanks mates
some news. I religiously clipped the wire before each new weld, and stayed in tight (3/8" or less) and it was better. LOL, splatter with fcaw cannot be reduced. I should get some of that anti-splatter spray, or just get a C25 bottle and be done
or get a bottle of evil-be-gone spray from the Tiny Music, Vatican Gift Shop
(dont cut out my paper heart...)

thanks mates
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2
Quote:

Originally Posted by CattleRustler View Post
thanks mates
some news. I religiously clipped the wire before each new weld, and stayed in tight (3/8" or less) and it was better. LOL, splatter with fcaw cannot be reduced. I should get some of that anti-splatter spray, or just get a C25 bottle and be done
or get a bottle of evil-be-gone spray from the Tiny Music, Vatican Gift Shop
(dont cut out my paper heart...)

thanks mates
Sorry to dig up an old thread, but....

Cleaning is always key to a good start. Chip & wire brush your previous welds. Also, clip the tip of the wire at an angle ( say 45 deg. ) and you should get better starts.

Always keep on eye on your contact tip to work distance. The contact tip is the copper tip the filler wire comes out of. Around 3/8 to 1/4" should work fine.
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3
I prefer SMAW. FCAW and GMAW just end up ticking me off for the exact reason OP stated lol
thanks for the posts guys.

yeah, in either process (fcaw and gmaw) I clip the wire tip at an angle before starting a new weld. It's less necessary when doing gmaw as compared to fcaw, and I weld solely with gas now (gmaw), but I still do it here and there depending on what the wire tip looks like after finishing the previous weld.

smaw is ok, and I still have my stick welder, but for smaller, more delicate things wire fed welding has great advantages. I doubt I will ever stick weld again but I may use the unit to convert it into a scratch start TIG welder. I have to get one of those DC Cheater boxes so I can convert the output from AC to DC (CC).
^^ Word. Definitely post up some pictures if you get that scratch start setup going. I should snap some pics of our welding lab here to get you guys drooling.
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will do. post some pics
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