![]() ![]() ![]() If you have a high wire speed and low voltage, there won’t be enough power to melt your wire into the weld. The reason these two settings must work together is because they are heavily related. The weld is so hot and fast that it literally sprays onto your material. Really high wire speeds paired with high voltages are considered a “spray transfer”. Lower speeds are great for thin material and smaller welds. The higher the speed, the more wire material is flowing out of the nozzle. Wire speed is measured in inches per minute. Depending on wire diameter and wire type (flux, hard wire etc), voltages generally range from 16-30 volts. The voltage is the amount of electrical power that is running to your arc. Beginners struggle with dialing these in, but it isn’t too hard. These are two settings that must work in harmony with each other. This can mean that you wasted money on a spool that is now unusable. It is often hard to fix a spool that is unraveled. Having a spool unravel on you will make you really want to dial in these tension controls for the next time. This will make it easier to change your spools in the future. Once you have a proper wire tension setting, you’ll be good to go. High tensions can cause the wire to break or jam on the way to the nozzle, and low tensions can throw the wire off the drive rolls or unravel your entire spool. This is the amount of pressure placed on the wire inside of the machine so it won’t unravel on you. MIG On Aluminum : Pixabay 2) Bad Wire Tension/Drive Roll IssuesĪll MIG machines have wire tension control. When the spatter starts to stick to your nozzle, the wire won’t be able to flow properly. This means you will spend more time cleaning your nozzle and less time welding. Second, close distances can cause the MIG spatter to clog up your nozzle or jam your wire. Watching your puddle will allow you to see how it is flowing. This is problematic because beginners should watch their puddle to see how it moves with their travel speed. First, it is much harder to see your arc this way because your nozzle is covering your weld puddle. Welding too close causes less problems, but it still isn’t ideal. You will know you have the proper distance when the wire is melting nicely into your metal as you push your puddle along. Having too far of a distance also means your welds won’t wet in, and the wire doesn’t have a chance to fuse into your material. This will leave broken wire strands stuck to your metal. This is because the wire starts snapping since it can’t fuse into the base metal. Wikimedia CommonsĪlso with long distances, your wire won’t melt into the piece and it will start making loud cracking noises. This is true for all welding processes.īy keeping your contact tip closer to the metal, you will ensure that the shielding gas can create a proper atmosphere to protect your weld puddle. If your weld isn’t shielded properly, then it will be quite weak. Too long of a distance causes problems because there is not enough gas flow to reach the arc. These contact tips have different diameters to accommodate multiple wire sizes. The contact tip is the metal attachment that your wire comes out of. Like all welding processes, proper distance between your electrode and your work piece can make or break a weld. Many new welders will hold the MIG contact tip either too close or too far away from their metal. 3) Improper Wire Speed/Voltage Settingsġ) Improper Contact Tip to Workpiece Distance. ![]() 1) Improper Contact Tip to Workpiece Distance. ![]()
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