Welding Tips and Tricks

I'm a beginner and have been practicing on 1/8" steel pates making lap joints. A good portion of the time the first 75% (3-4") of the weld is the smooth "bacon frying" sound, and then it sputters and pops the rest of the way, though I don't think I'm changing my travel rate or gun angle or stick out.

I've tried to isolate the issue - ground clamped directly to my work piece rather than the table, prepped the metal well with a 120 grit flap disc, made sure my gas (C25) is on and flow is about 20 cfh...

I'm using a Miller 211 with the suggested setting for voltage and the machine automatically picking wire feed speed. I'm using Hobart 0.030 ER70S-6 wire. I'm pulling slightly (~10 degrees?) so that I can get a good view of the bead.

Am I just accidentally changing my speed or position of the gun and not realizing it? Any tips for a beginner?

It could be as simple as your distance (contact work distance) is becoming too long. Can you focus on keeping the gun the same distance and get better results?

Another thing to understand is the wire speed. When it becomes too slow, it begins sputtering because it’s not maintaining the arc. Do you feel the wire “stabbing” when the sputtering happens?

Yes, I do feel the wire stabbing and trying to push my gun back a bit when the sputtering occurs.

Increase the wire speed and try again.

andyb wrote:I'm a beginner and have been practicing on 1/8" steel pates making lap joints. ...........
I'm using a Miller 211 ............

are you running on 120v or 240v?
whats the wire feed speed?
can you look over and see what amperage and voltage your welding at?

i suspect its the welder running out of power.

How close to the end of the nozzle is the contact tip if your to close to the tip it can over heat and begin freeze up some flux nozzles are shorter from my experience the tip should be recessed about 1/2-1/4 inch just a thought

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Turn the auto wire feed speed off and try again.

That sounds like my prostrate.