Whats wrong with my Hobart Mig welder? PICS

[modernceo]

So I was doing some practice welding today on tubular steel.

Im using C25 gas mix, with my Hobart Mig 140 welder.

Heres my first test weld.

http://www.modernperformance.com/cory/Misc/weld/P1010070.JPG

Looks good, good penetration, not very pretty,and the welds arent very straight. But regardless, not bad for someone who just learned to weld 3-4 weeks ago and is doing it as a hobby right ?

Anyways, after making several welds I was happy with, the welder makes a unusual arc sound, then pause, then arc, then pause noise.

The wire seems to melt as soon as it hits the weld surface, and its not penetrating the weld surface at all.

Heres a picture:
http://www.modernperformance.com/cory/Misc/weld/P1010068.JPG

I dont understand how I havent made any settings changes, the machine is definitely not overheating, and the wire feed doesnt seem too fast.

Its almost as if the machine isnt getting enough power to penetrate. Its just melting the wire.

Before one of you say "Your holding the stick too far away from the surface, I seriously doubt its that, im fairly close".

Im also in a garage, where its probably 55-60 degrees so I cant imagine that its too cold.

What do you guys think ? Id really appreciate your input.

[MichaelP]

Make sure the gun cable is more or less straight.

[dda52]

check and blow out the liner

check drive roll tension

check the spool...all nice and tidy or loose strands causing binding?

check or just change contact tip

That is what pops into my head immediately when that happens. That's all I have at the moment.

[Rocky D]

Make sure you have a good clean ground, and all your connections are tight. Place the ground clamp as close to the weld joint as possible.

[Clay Walters]

I'm with Rocky although everyone's recommendations are good. When I get that type of symptom its usually remedied by hooking the ground directly to the piece near the weld point and then hitting the weld area with a flapdisk to be certain I'm welding clean metal. It appears you also have a much larger heat sink with the pieces you last tried to weld than the small practice piece.

Regards,

Clay

[Trickasabrick]

Is that paint on the tubing? Can't tell from the picture. Make sure you have a clean joint, migs don't like dirty metal.

[Hobart Expert Keith]

Make sure you are still getting gas through your gun. Looks like there is no gas coverage.

Keith

[Critter]

I had that with the second bead on my 140, but there was too much wire out, cut it off and it took right off.

[stronics]

I'm with Keith on this. It doesn't look like any gas coverage. Plus I'd turn that puppy up wire feed about 65% and try it. I'd turn up the wire feed pressure too.
David

[modernceo]

I replaced the tip, increased the wire feed speed, and its working beautifully now!

:D

Im going to post photos of my project im working on shortly.

[hogan]

your gas coverage looks good. what is the duty cycle on your machine?

[Rocky D]

HH 140, is 20% @ 90amps

[SavageSunJeep]

I have seen that before, LOL
Being a new guy at this I fixed it each time I saw it:

1) Forgot to turn on my gas, tied orange streamer on the gas tank...fixed it

2) Replaced the tip from too many hot welds that welded my wire to the tip...fixed it

3) Fine tuned, read, too hot so backed down on voltage a bit, got better, backed down a little more...fixed it

4) Get the ground CLOSE to your welding area and make sure it is clean and well grounded

4) Remember the 80/20 rule (good welder told me this) for every 2 minutes of welding time you should spend 8 minutes cleaning and prepping your work as you go. My welds are not always pretty but I have yet to have one fail, hope I never do of course. ;)

[tigamajig79]

i weld with a Millermatic 130 at my shop........the wire tends to zig zag around to puddle when A. the tip is "sloppy" oval shaped B.the driveroller is too tight and it pinches the wire flat. or BOTH...the roller is best set just tight enough to where you can pinch the stickout to stop the wire and NOT make a birdnest
I wasted alot of wire before I learned tha one.;)