Further Down the Rabbit Hole, or Plasma Cutters, MIGs, and Chop Saws oh my!

[ACHiPo]

I may have missed it in an earlier post, but are you running the machine on 110 or 220? And as suggested above are you sure that your setting are matched with the input voltage?

I'm running 220V. It sounds like I've got a shield gas issue. I'll troubleshoot this weekend unless I get home unusually early tonight.

 

[ACHiPo]

I have the same machine that you just purchased. Based on my experience I think bss1 and Rustrp are on the problem. It looks like a shielding gas issue. If the metal is clean to start with (no mill scale) then lack of shielding gas is the first probable cause for the porosity.

I'm don't know how to compare PSI to CFH - with my machine 15 CFH seems to be the sweet spot. If your LWS store is convenient I would stop by and "trade" them that regulator for a good flowmeter.

You're making me wonder if I misread the gauge--it looked like a pressure regulator gauge, but it may be calibrated for flow? I'll take another look.

 

[Rustrp]

I have the same machine that you just purchased. Based on my experience I think bss1 and Rustrp are on the problem. It looks like a shielding gas issue. If the metal is clean to start with (no mill scale) then lack of shielding gas is the first probable cause for the porosity.

I'm don't know how to compare PSI to CFH - with my machine 15 CFH seems to be the sweet spot. If your LWS store is convenient I would stop by and "trade" them that regulator for a good flowmeter.

I agree that 15cfh will suffice but the $$ saved on the difference between 15 & 25 isn't worth a compromised weld. I know I'm approaching this from a business standpoint of time is money.

The mill scale on his test pieces isn't enough to cause the porosity he's getting but I agree, removing it does improve weld quality.

 

[ACHiPo]

Just called the welding supply store--the regulator is indeed calibrated in flow, not pressure, so I'm running way too high. Will try turning it down (as well as make sure that it is indeed flowing).

 

[Rustrp]

I may have missed it in an earlier post, but are you running the machine on 110 or 220? And as suggested above are you sure that your setting are matched with the input voltage?

The newer 211 has a rectifier power source and can use 110 or 220, but I'm not sure if the older transformer powered units have the same MP advantage.

 

[Rustrp]

Just called the welding supply store--the regulator is indeed calibrated in flow, not pressure, so I'm running way too high. Will try turning it down (as well as make sure that it is indeed flowing).

It is possible to get porosity with the gas turned up to high which would cause turbulence and pull the surrounding air into the weld area. That's the theory but I have never seen it and I can guarantee the porosity in your photo isn't caused by the flow rate being too high.

 

[ACHiPo]

It is possible to get porosity with the gas turned up to high which would cause turbulence and pull the surrounding air into the weld area. That's the theory but I have never seen it and I can guarantee the porosity in your photo isn't caused by the flow rate being too high.

I need to get out to the shop to figure out what's going on. Maybe tonight.

 

[ACHiPo]

Got it sorted! Confirmed no leaks anywhere (there was still gauge pressure/flow registered), then fired up the welder and advanced the wire--no hissing. Sure enough the pressure/flow was 0 when the trigger was depressed. Keeping the trigger down, I cranked up the regulator to 18 CFH and confirmed hissing. Results were much better. I still have a lot to learn and practice, but the beads are at least beads and not pumice! I also got the steel up off the ground. The first bead is at the top, the last at the bottom. In addition to my lack of skill, getting a straight, consistent bead sitting on the ground ain't easy.


Now to get the band saw sorted!

 

[Rustrp]

In addition to my lack of skill, getting a straight, consistent bead sitting on the ground ain't easy.

So the first project coming up is a work bench. Looking good! You didn't comment on the wire size but I'm guessing .024"-.030". Keep us posted on the progress.

 

[ACHiPo]

So the first project coming up is a work bench. Looking good! You didn't comment on the wire size but I'm guessing .024"-.030". Keep us posted on the progress.

0.30" wire. Yes, a welding table (workbench) is next. Then a mobile base for my lathe bench.