Sheet Metal Welding

Jiles · Mar 30, 2016

I have a Hobart 135 Handler mig welder.
I am trying to weld some tractor sheet metal and I am having a problem.
I am using 030 flux core wire and I have always got a fairly acceptable job welding this thin metal.
Today it just burns a hole! I have it set as low as it will go, same as before, and it seems too hot. I tried different metal, slightly thicker, and had same results.
I have owned the welder for about 12 years, maybe longer, and it has had about two 10 lb rolls of wire ran.
Anyone have any experience with this particular model?

37chief · Mar 31, 2016

Someone said to clamp a piece of copper behind the weld. It will take some of the heat. Stan

MarkB_MI · Mar 31, 2016

Remember, the current setting on a wire-feed welder is labeled "wire speed". Slow it down.

Stephen Newell · Mar 31, 2016

I've always had trouble welding sheetmetal. I turn the temperature down as low as I can on the welder but unless I weld small spots at a time it tends to burn through. I might make a weld about 3/4" long and skip over three or four inches and do another spot. Then let it all cool and start filling in with short welds.

Alan K · Mar 31, 2016

I agree, sometimes it will do that. I have found that some of the spools of wire that I
replaced had a higher heat rating than the last one so I had to learn how to weld with it
all over again.

Geo-TH,In · Mar 31, 2016

I use 023 wire and gas, no flux. Metals
and wire can't have any rust. Work for
spot welding body panels.

Burning a hole, too hot.

coshoo · Mar 31, 2016

Yep, wire's too thick, and flux core is always more difficult for me than gas and solid wire. I have one roll of flux core, and it will apparently last me for the duration. Every once in awhile I try to use it (like outside when its windy), and it reminds me of why I dislike it so much, so back on the shelf it goes.

TimV · Mar 31, 2016

Jiles: I've got the same welder and have had it for about 15 years. I keep it loaded with 0.023" solid-core and use gas. Remember that flux-core uses the opposite polarity of solid-core, and you need to swap the leads if you swap wire types. I have a AC/DC stick welder for anything too heavy for the little MIG, but it's been a very good welder. As noted, you can back it with a chunk of copper (even a piece of pounded-flat water pipe will work in a pinch) but you'll need to have everything clean--even flux-core doesn't like rust, and it's very easy to burn through thin metal because even a tiny amount of rust pitting will make the metal so thin that it will burn a hole through the minute you try to weld it.

Jiles · Mar 31, 2016

I am not asking how to weld with this welder.
This machine has worked properly for years but something has changed.
Why is it too hot in the lowest setting?--Bad current setting dial?
Is there any way to check welding voltage with a meter?

Tiger Joe · Mar 31, 2016

I have the same welder and regularly use it for sheet metal.

what gauge is the sheet metal? that welder is not rated to weld thinner than 18 gauge with .030 flux core.

Tiger Joe · Mar 31, 2016

adding to what others said, did you recently swap wire around and forget to change the polarity?

machine should be set at 1/10- lowest on both.

again, im not sure what gauge you consider sheet metal, but the wire you have is not recommended for it.

According the 135 handler manual, the only wire recommended for 22 gauge is .024 with gas

tom stalker · Mar 31, 2016

Try the .023 wire

I use 023 or 030 depending on metal thickness I am welding

More amps go thru the larger diameter wire as compared to the small diameter wire

No idea why you could weld sheet metal once and not again with the same machine

should be easy to see if wire feed speed adjustment still works

test amp adjustment by arc size

MarkB_MI · Mar 31, 2016

>Why is it too hot in the lowest setting?--Bad current setting dial?

I repeat: Current is adjusted with the wire speed control. The other knob does not control current, it controls voltage. (Wire feed, unlike stick and TIG, is a constant voltage process.) Wire speed is your primary control. Once you have the appropriate wire speed, you can adjust the voltage up to eliminate sticking or down to reduce spatter.

showcrop · Mar 31, 2016

I have been welding a lot of 20 gauge using the .023 with gas. I never try to run a bead. I was taught to make just little dots and gradually fill in.

Jiles · Mar 31, 2016

(quoted from post at 02:58:56 04/01/16) >Why is it too hot in the lowest setting?--Bad current setting dial?

I repeat: Current is adjusted with the wire speed control. The other knob does not control current, it controls voltage. (Wire feed, unlike stick and TIG, is a constant voltage process.) Wire speed is your primary control. Once you have the appropriate wire speed, you can adjust the voltage up to eliminate sticking or down to reduce spatter.

That is something I forgot. Been over two years since I have tried to weld thin metal and I had just forgot.
I will try again tomorrow.
THANKS for that reminder.

Sheet Metal Welding

Jiles

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37chief

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MarkB_MI

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Stephen Newell

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Alan K

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Geo-TH,In

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coshoo

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TimV

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Jiles

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Tiger Joe

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Tiger Joe

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tom stalker

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showcrop

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Jiles

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