I tried the Twenty Gauge .030 Metal Core wire by Harris, as recommended by Ernie. It's a gas shielded wire with flux in the metal core. It's primarily designed to reduce burn through on thin sheet metal. However, the additional wetting and penetration due to the metal powder core and flux additives is very helpful, especially working outside with less than perfect metal prep and fit. Unfortunately, this is a single pass wire, only recommended up to3/16" thickness. I've been looking into .035 low alloy metal core wires for fabrication. Looks like a good choice for all position welding with the large three phase box at work, which will have no problem supplying 200 amps or more as needed. What I'm wondering is if an .035 metal core wire will work at a lower amperage with a 230V welder such as a Hobart Handler 175. The lowest suggested amperage I've seen on manufacturer's websites is 135 amps,which I think is at the very top of what the Handler can provide. The wire is not available in small rolls for little machines, 33 pound steel wire coils is the smallest offered. That can be overcome by transferring the wire to a smaller coil, but will the wire work well at lower settings? Is there any reason it can't perform like .035 solid wire but with some additional shielding/penetration? Tech support at a couple manufacturers was reluctant to stray from the specific recommended applications. This seems like a natural application for metal core wire for multi-pass work with smaller machines. I hope we see more metal core offered in small rolls suitable for small 230V machines. In the meantime, does using .035 metal core low alloy at lower parameters sound feasible in a small machine?
18 years ago