welding contact tip question

[Dodgenut64]

Ok, i want to get started on trying out my welder. I have a question. IN the instructions it says make sure the wire size matches the contact tip size. I got .024" wire with the welder, but the tips i got with it are .030" and .023". Im new at this and would enjoy taking a class, but dont have the money right now so im trying to learn it myself. Which tip do i use? i would think id need a tip that says .024" to "match the wire" as per the instructions, but i didnt get any tip with the welder of that size, all i got was .023 and .030 size contact tips. Any help would be awsome. Thanks

 

[Rob]

As you said, you should have an .024 tip for .024 wire, tips are very cheap so if it's at all convenient go to your welding supply place and get a few. If it isn't convenient try the .023 tip, just pull the trigger a few times to see if the wire passes freely, if it doesn't you can use the .030 tip although it isn't ideal. As you are new to this practice a lot on scrap metal, you can't run beads on sheetmetal without warping the panel. it's a series of tacks spaced out and slowly closed in. You have to go slow, if you rush you'll have a buckled panel and you don't want to learn how to fix that :banghead:You need about a 1/16" gap as the metal will expand when you weld it causing it to bow in or out if your patch is too tight. It takes a bit of practice to set your wire speed and voltage, it should sizzle not pop. Have fun :toothy7:

 

[Rick@Laysons]

Hi James,

You might want to go to a welding supply store and get a roll of .023" solid welding wire to use. Most of the time, the wire that comes with a new welder is the "flux core" type of wire which is totally unsuitable for sheetmetal on cars. You need a .023" solid metal wire with a gas bottle of CO2 or "tri-mix" gas in order to do a good job. Keep the tip size and the wire size matched, it just doesn't work too well if the tip doesn't match the wire.

One other thing, while you're at the welding store, get an aerosol can of anti-spatter spray and keep the tip sprayed down frequently. You will not get as many berries and your welding tip will last much longer without as much build-up on the tip.

Welding isn't hard, it just takes practice. I was a journeyman welder for 24 years before I started working here.

 

[Dodgenut64]

Thanks for the tips guys, ill stop by the welding supply shop friday and pick up some .023 wire. I have some scrap metal to practice on and ive already got my gas mix. Im gonna practice abunch before i even touch my car. I guess Miller tossed in that .024 wire for the flux core stuff like you said Rick. Thanks for the gap tip Rob.

 

[crackedback]

Here is a good site to get consumables, nozzles, tip, adapters.

http://www.htpweld.com/products/mig_gun_parts/miller.html#6

I buy most of my stuff including wire from them and always great service/pricing.

You shouldn't have an issue using the .023 tip with .023-.25 wire. I've used them all the time with no issues. As mentioned, make sure it feeds cleanly.

You really need to use a gas set up to do sheetmetal work. Flux core burns real hot in comparison to solid core wire. That's why when you look at the thickest metal your welder can handle, flux core is capable of fusing thicker pieces than the same size solid core wire.

Straight CO2 makes for a hotter arc/puddle. I'd go with the standard C25 (CO2/Argon) mix. Everybody has an opinion on this as well. Mine is that you want the smallest Heat Affected Zone (HAZ) as possible on thin gauge steel. Use the gas that provides the coolest puddle. That's why TIG is so nice, you can control the heat and minimize your HAZ.