What's up with this?

You did change drive rolls and contact tip?? Odd that you have trouble downsizing. Usually it is the other way round. Randy

BUT, I have a problem running the smaller wire. .025 or .023 IIRC (I'm too lazy right now to run out to the shop and look)

Recently, I ran out of .030 wire, my regular choice. So, I put on the smaller wire. I have more trouble getting it to run right for me. I start at the suggested settings. But my welds look like dog turds, or I blow a hole.

So, today, I went and got a roll of .030 wire, and will change it out tomorrow.

I need to put on contacts and then +2.25 reading glasses to see perfectly for welding. Right now, I'm low on contacts, so just use my bifocals, which is like trying to write looking in two mirrors. Sheesh, getting old is the pits.

I have some welding to do tomorrow building some new fancy fence to go with our new landscaping, and will do the whole deal with contacts and glasses to try to see what's up.

Any ideas or pointers?

Ideally, I like a spray arc, with the wire not blobbing up on the molten tip, nor stabbing into the puddle so I can feel it. I know it's a balance of heat settings and wire speed. But I just can't find the right one for .023.

Thanks in advance

Steve

Did those things. The wire just burns a lot differently.

Steve

And the wire isn't accidentally fluxcore which you're running like solid i.e. at the wrong polarity?

I don't believe E70S-6 is fluxcore wire, IIRC.

Steve

Well, *something* is going on. I know it's a pretty low level question, but occasionally questions like that gotta be asked.

GWE

Quite a late answer: Calculate the sectional area (0.8mm and 0.6mm wire):

That is nearly the half! Now you need nearly double the wire-speed for the same weld. The higher speed quenches the arc. Furthermore, the wire has nearly double the resistance. A lot of heat goes into the wire and not directly into the puddle and, as MIG/MAG is constant voltage, the current drops. There is a usefull range of amperage you can run through a wire, you are out of the range. You could try to reduce the wire stickout ...

Nick

I found the problem. I just needed to open up the flap and set it at the right settings. I had the flap inaccessible with a hold down cord.

The .025 runs a lot different than the .030. You have to watch your puddle and wash around a little more. It does give a nice small even bead, though. Once you get the settings right, that is.

Steve

Oh, good. Then it isn't only me that has problems with it. Actually, after I got the heat set right, and got my good vision setup on, it was a lot better. It really didn't take me much time to get going once I had the right setting.

Yet, as with any MIG welding, the settings will change according to what you are doing, position, and other factors.

Steve