Welding Tips and Tricks

I've been having a problem with the wire burning back an clogging the tip. I'm running in spray like your supposed to (about 23V) and even if I push way to much wire I still get the same problem. I also use one size bigger tip than the wire to keep from having jam ups. Any ideas anybody?

http://www.weldreality.com/spray%20transfer%202.htm

nickn372 wrote:I've been having a problem with the wire burning back an clogging the tip. I'm running in spray like your supposed to (about 23V) and even if I push way to much wire I still get the same problem. I also use one size bigger tip than the wire to keep from having jam ups. Any ideas anybody?

I didn't read the whole article, but it seems to be very informative.

What is your wire size, ipm, and gas? I do ALOT of spray and might be able to help. At 23v, depending on wire speed, you might actually be in globular and not spray.
A larger contact will not help, rather it can hurt. Remember it is called a "contact tip" be cause it gives electrical contact through it. I know a guy that tried to same things you are doing using spray. Running .052 he was frying his tips and getting them too hot, so he stepped up to the next size and had more problems with it.
-Jonathan

Right now I'm just running .035 cuz its all 1/8" stuff but I get the same thing with .045 (3/64). I work off of an engine drive and I've been thinking this may be a partial cause cuz the wire stays live after the spool drive stops. More than likely if I had a contactor toswitch off the live current my issue many disappear. But I just wanted to see if I'm missing something in my process.

Most of the time when I am having burn back issues with my 30A it's because I am not paying attention to my stick out. If I get too short it fries the tip when I stop. I also disconnected the hot start function on my 250x which helped on burn back at the start of the arc. My new 252 has been much easier to work with than the 250x. I use mainly 3/64" wire (.047 tip).