Welding Tips and Tricks

Hi everyone!

We recently got a structural project, and it has to be done with FCAW process; The base is st37 and it's pretty clean metal. We have ordered ESAB OK Tubrod 15.13 spools for the job. Honestly, I have no idea what is the product date of these spools since they are almost never used in our country except shipbuilding. Now the problem is that every time we have a vertical or overhead pass, we are facing with porosity, and when I'm saying porosity I don't mean good old wagon tracks that you get now and then, I'm talking about surface cluster porosities. We absolutely don't have any problems in the cover pass of open V groove joints or flat surfaces or horizontal T-joint. We tested both CO2 and C25 and also M21. None is giving us a better result. Tried to change the gas flow. 15 Lit/Min up to 25, nothing happened.
Some people mentioned that these are Voltage sensitive but we already have tested a wide range of Voltage output (from 19 up to 26). my guess is that wire is the problem, the thing is that we have ordered like 12 of em and the contractor is not gonna pay another dime to test a different spool, somewhat blaming the welders, that is us. The good news is that the spool wheel is metal and we can bake it, so what do we have to do with this situation? appreciate any response.

Be careful baking flux core it will likely affect the flux inside the wire.

What does ESAB have to say about it? I'm guessing you already called one of their technicians or customer service reps?

Any update?

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Simclardy wrote:Any update?

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Nope, just another askhole.

Lol. I replaced a dump truck bed liner this week and was having issues with my excel arc 71 (e71t-1c/m). Anyway i was trying to brush up on troubleshooting fcaw-g.
Im pretty sure it was the rust and crap on the metal all though it surprised me both ways, sometimes it layed a better than expected bead and sometimes i expected better. I ended up using 6010 for a good portion of the project.
Do you know of a comparable wire? Looking for a wire that can handle a bit of dirty metal. I can't run e71t-8 because my machine can't handle amps or 30lb rolls.
(Multimatic215)

I have a roll of e71t-11 not sure why i did not try that on this project but i will give it a go again.
Cheers

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Simclardy wrote:Lol. I replaced a dump truck bed liner this week and was having issues with my excel arc 71 (e71t-1c/m). Anyway i was trying to brush up on troubleshooting fcaw-g.
Im pretty sure it was the rust and crap on the metal all though it surprised me both ways, sometimes it layed a better than expected bead and sometimes i expected better. I ended up using 6010 for a good portion of the project.
Do you know of a comparable wire? Looking for a wire that can handle a bit of dirty metal. I can't run e71t-8 because my machine can't handle amps or 30lb rolls.
(Multimatic215)

I have a roll of e71t-11 not sure why i did not try that on this project but i will give it a go again.
Cheers

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What was yout ctwd and your gas flow rate?

30cfh 1/2" ctwd.
https://www.hobartbrothers.com/product- ... rade%3B+71

I could not link the spec sheet but this is the link to the pdf.
I used the voltage and amperage recommended and ctwd recommended with a drag motion.
Of course when you are welding in all sorts of positions the ctwd can be deceptive.


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Simclardy wrote:30cfh 1/2" ctwd.
https://www.hobartbrothers.com/product- ... rade%3B+71

I could not link the spec sheet but this is the link to the pdf.
I used the vintage and amperage recommended and ctwd recommended with a drag motion.
Of course when you are wondering in all sorts of positions the ctwd can be deceptive.


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wire diameter?

.035. I was using 23.3v and about 360 wfs

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