Can FCAW replace SMAW for most things?

I use Stick 90% of the time for stuff I do (various repairs, blacksmith tools, welding tables, etc.).

But, I have this beautiful MillerMatic 252 I bought recently and have been using it more and more for its speed and anytime I have some aluminum to repair (large tent poles, bases for tables, etc.).

Now that my main stick machine has been down (some of you may have seen my posts about my Miller DialArc 250), I got to wondering if I shouldn't run flux core in my MM 252 to do the jobs for which I've traditionally used Stick.

Furthermore, should I lean toward gas-shielded for most of it or go with the self-shielded. I run C25 for my regular MIG and 100% Argon for the aluminum. I would like to not have to buy yet another gas cylinder if possible.

Ideas? Opinions? Words of wisdom?

Thanks,

rvb

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)
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Fluxcore should work great as a stick replacement. It is a process that is very similar to stick welding, runs hot, etc.

Reply to
Ignoramus26200

Far better choice would be dualshield wire, or a fluxcore wire which uses a gas shield. That's what's used in heavy industry as a stick replacement, when there is a stick replacement.

Grant

Reply to
Grant Erwin

What gas does each require; CO2?

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

I could argue either side of the flux core vs stick welder debate. Each one has pro's and con's. I use stick, MIG, Tig and flux core, but not dual shield (I consider dual shield to be a high heat production process, not a repair process, plus my MIG won't go hot enough)

I prefer stick for repair: lots of rod options, lots of heat options, lots of fill vs freeze options, much higher tolerance for dirty/greasy/rusty materials, much less chance of laying a bead on top of the material with no penetration, much longer cables, and no issues with wind blowing the shielding gas away. Downside is more spatter, slower metal deposit.

Mig is king for clean metal and new construction. It's also one option for stainless and aluminum.

My flux core is limited to my 120 volt portable welder. If I have the

240 volt units, I'll either use the stick for repair or the Mig for new.

Tig is for thin wall tube frames, stainless, and aluminum.

Reply to
RoyJ

Gas Shielded Flux Core (ESAB Dual-Shield, Lincoln Outershield) rules the heavy fabrication industry, for quality speed and ease of use. It is restricted to indoor, just like MIG and TIG. The most common gas used for Gas Shielded Flux Core is C25.

Self Shielded Flux Core (ESAB Coreshield, Lincoln Innershield) rules the outdoor construction trade. Both can be run in your 252, but they both require higher current than MIG, so they tend to beat up small MIG guns. If you don't have a heavy duty gun on your 252, then stick with smaller wires, like 0.035" ESAB 7100-Ultra Dual-Shield, my favorite.

Same deal with Self Shielded Flux Core. Larger wires use a lot of current and will cook the standard gun that Miller puts on 252's. I like Tregaskis Toughguns in the 400 amp range for flux-core wires. I have one on my Betamig 250 so I can run 0.045" dual-shield all day long. At school I put a 400 amp Miller Roughneck gun on our Millermatic 300 so it can run Dual-Shield.

Dual shield is really hot and clean, and the flux falls off to leave pretty pretty welds with little or no spatter.

When running Dual-Shield use oversized tips or they will erode rapidly and start sticking. So for 0.035" wire use 0.040" tips and for 0.045" wire use 0.052" tips.

Reply to
Ernie Leimkuhler

Is there a low end, home shop sized version that matches or beats stick?

I couldn't find flux-core stainless in less than $400 rolls so I used

309 and 312 rods.

jw

Reply to
Jim Wilkins

Hi Rick,

The big upside to all tubular wires, fluxed or metal filled, is speed and ease of use.

The downside is they will run farther out of parameter than solid wires, cost more, and the big one for the small shop is the core begins degrading after opening the package.

A typical E71T-1C /1M (C=Co2 / M=Argon mix gas dual shield, ) can have significant oxide content with elevated hydrogen in the weld, after laying around for a week or two in the open air (any condensation is a killer).

This is supposed to have improved with seamless wire tube manufacturing but the docs are still going to warn you about storage.

Matt

Reply to
matthew maguire

7018 needs to be stored in airtight tubes too.
Reply to
Jim Wilkins

Ahhhhhhhh good to know. I don't fire up that machine much (probably due to more comfort and confidence with Stick at the moment) and that would be a killer. The machine is in an unheated barn so condensation happens despite my efforts to minimize it with a cover, put it in the driest spot, etc.

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

True, but I find these rods less sensative to moisture than I was led to believe. I have them inside the package in a toolbox.

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

Good information. Thanks.

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

Thanks for the great info, Ernie.

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

You may want to either buy a desiccant wheel dehumidifier, or alternatively put a lightbulb under the welder.

Reply to
Ignoramus15648

Thanks. What I really need to do is wall up the side of the barn that is my workshop and seal the sliding barn doors to minimize the weather getting in.

Actually, what I need to do is build another barn for the horses, hay, and wife, keep the current one for mine, and weather-proof it.

Don't tell the wife on me or I'll deny everything! :)

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

We use a 75/25 Argon/CO2 mix. It gives good penetration with less spatter.

I have to admit, though- We are getting away from dual-shield and running a lot more pulse due to air quality requirements and less time spent post-weld cleaning.

Reply to
TinLizziedl

Wrong emphasis here - build a custom already-weatherproof workshop & leave the current barn for the horses ;-)

Reply to
Phil

Unfortunately it is hard to find amny alloys in small rolls of self-shielded flux-core and gas shielded flux-core.

It is a tough market. I have spooled my own small spools from larger spools for my spoolgun, but it is hard to buy many types of wire in small amounts.

Harris has their "20-gauge" wires, but they are hard to find.

Reply to
Ernie Leimkuhler

Hmmmmmmmmmmmmmmmmmmmmmmmmmmm you may just have something there!!!

-- As Iron Sharpens Iron, So One Man Sharpens Another. Proverbs 27:17

Reply to
Rick Barter (rvb)

To me the wider variety of stick electrodes argues for AC+DC arc over MIG for doing a variety of small jobs in a home or repair shop.

Jim Wilkins

Reply to
Jim Wilkins

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