mig and flux core tips and techniques, equipment, filler metal
bilt2spd
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I am looking for some suggested settings for using .025 solid wire to weld 20, 18, and 16 gauge metal. The calculator that Jody posted is inaccurate for thin metals. I do not have a chart inside the welder because I have a Miller D52-D dual wire feeder and an XMT 304 CC/CV power supply. Looking for actual settings that people have used with success. Thanks.
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bilt2spd wrote:I am looking for some suggested settings for using .025 solid wire to weld 20, 18, and 16 gauge metal. The calculator that Jody posted is inaccurate for thin metals. I do not have a chart inside the welder because I have a Miller D52-D dual wire feeder and an XMT 304 CC/CV power supply. Looking for actual settings that people have used with success. Thanks.
Joint configuration/position?
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bilt2spd
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Mostly 1" square tubing, t and butt joints, all positions, and welding sheet metal to it.
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For T- and butt-joints using 0.023" ER70S-6 on 16ga, I have previously used 270 IPM/17.5V ±15% depending on a couple other factors. I don't do much below that thickness
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bilt2spd
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That's what I was looking for, a good starting point. Thank you so much.
sbaker56
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    Sat Feb 08, 2020 12:12 am

I'm assuming you're using 75/25 not Co2 right? I might add that you often need to increase your travel speed signifcantly on thinner metal, and it really helps to do short runs, because you'll often blow suddenly blow through 4-5 inches into your weld even though you had the same stickout and travel speed because the surrounding metal heated up.
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Which gas are you using? That would be helpful to know. Also I agree with the Oscar's starting point suggestion. You can try that and tweak a bit from there. Which machine do you have and do you have fine tuning settings available?
tweake
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good point about the gas.

high argon mix is better for thin stuff.
90/10 or 93/5/2.
tweak it until it breaks
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