Gasless Flux Core Welding Tips, Make Better Cleaner Welds

Mike festiva
8 Apr 202216:56

TLDRIn this video, Mike Festiva tests five different flux core wires from various brands to determine their quality and performance. He shares tips for new flux core welders, including the importance of travel speed and the correct polarity setup. After welding tests on 11-gauge steel, he evaluates the spatter, weld quality, and ease of cleaning for each wire. The Hynade, Forney, and Yeswelder wires stand out for their smooth operation and weld quality, while the Lincoln and Vulcan wires are less favored due to more spatter and inconsistent weld beads. Mike also recommends the Hynade 140 amp flux core welder for its auto-set feature and value for money.

Takeaways

  • 😀 Mike Festiva introduces a video about testing five different flux core wires to determine their quality and performance.
  • 🛠️ Mike recently purchased a Hynade 140 amp flux core welder from Amazon and found the included flux wire to be of high quality with less spatter.
  • 🔍 The video will cover tips and techniques for flux core welding, especially useful for beginners.
  • 🧵 The tested wires are all .030 in size, including brands like Lincoln, Vulcan, Forney, Yes Welder, and Hynade.
  • ⚙️ A key feature of the Hynade welder is its dual voltage capability and auto wire speed setting based on voltage.
  • 💡 When welding with flux core wire, a slower travel speed is necessary compared to solid wire and shielding gas due to the hollow nature of flux core wire.
  • 🔌 For flux core welding, the welder should be set to DC electrode negative, unlike solid wire MIG welding which uses DC electrode positive.
  • 📏 It's recommended to have more stick out (from 3/4 to 1/2 inch) when welding with flux core wire compared to solid wire.
  • 💨 The saying 'if it's got slag, you drag' emphasizes pulling the flux wire to avoid incorporating flux into the weld, which can cause porosity.
  • 🛠️ Cleaning the weld joints with an angle grinder and flap disc before welding is crucial for better results, as flux core welding is more forgiving with rust or dirty metal.
  • 📊 After testing, the Lincoln and Vulcan wires were found to be less satisfactory, while Forney, Yes Welder, and Hynade performed well with minimal spatter and smooth operation.
  • 🏆 Mike's final verdict ranks the wires from worst to best based on performance, with Forney, Yes Welder, and Hynade being the top choices.

Q & A

  • What is the main topic of the video?

    -The main topic of the video is testing and comparing five different makes and brands of flux core wire for gasless flux core welding.

  • Why did Mike Festiva decide to test different flux core wires?

    -Mike Festiva decided to test different flux core wires after noticing that the Hynade wire that came with his new welder produced less spatter and had a shinier appearance than other wires he had used before.

  • What is the first tip Mike gives for welding with flux core wire?

    -The first tip Mike gives is to weld at a slower travel speed with flux core wire compared to solid wire and shielding gas, and to watch the weld puddle closely to ensure proper weld buildup.

  • What is the significance of the DC electrode negative setting on a flux-only welder?

    -The DC electrode negative setting is significant because it ensures that the MIG gun is negative and the welding clamp is the positive lead, which is necessary for proper flux core welding and to avoid poor welding results.

  • What is the purpose of having more stick out when welding with flux core wire compared to solid wire?

    -Having more stick out when welding with flux core wire helps to manage the increased spatter that can occur and allows for better control during the welding process.

  • What is the saying about slag when welding with flux, and what does it mean?

    -The saying is 'if it's got slag, you drag,' which means when welding with flux, you should always pull the wire rather than push it to avoid incorporating flux inside the weld, which can cause porosity.

  • What is the importance of cleaning weld joints before welding with flux core wire?

    -Cleaning weld joints before welding with flux core wire is important to remove rust, paint, grease, or dirt, which can affect the quality of the weld. The saying 'if it's worth welding, it's worth cleaning first' emphasizes this point.

  • How does Mike evaluate the performance of the flux core wires after welding?

    -Mike evaluates the performance of the flux core wires by observing the amount of spatter, the consistency of the weld bead, the ease of cleaning off slag, and the overall feel of the wire when used with the welder.

  • Which wire brand did Mike find to be the worst in his tests, and why?

    -Mike found the Vulcan wire to be the worst in his tests due to its inconsistent weld bead, poor machine feed, and the most spatter among the tested wires.

  • What are Mike's final thoughts on the Lincoln, Forney, Yeswelder, and Hynade wires, and how does he rank them?

    -Mike's final thoughts are that the Lincoln wire, despite being the most expensive, did not perform as well as the others. He found the Forney, Yeswelder, and Hynade wires to be superior, with all three running smoothly on the machine, but he noted that the Forney wire felt slightly crisper and smoother.

Outlines

00:00

🔥 Introduction to Flux Core Wire Testing

In the introductory paragraph, Mike Festiva welcomes viewers back to his channel and outlines the aim of the video: to test and compare five different makes and brands of flux core wire. He explains that the quality of flux core wire can vary, affecting spatter levels and welding quality. Mike shares his recent experience with a Hynade 140 amp flux core welder purchased from Amazon, which came with a spool of flux wire that performed exceptionally well with less spatter. This experience motivated him to order and test different varieties of flux core wire, including Lincoln, Vulcan, Forney, Yes Welder, and another Hynade wire. The paragraph concludes with Mike preparing to cut coupons for the welding tests and mentioning his plasma cutter and DIY water table projects.

05:04

🛠️ Welding Tips and Initial Wire Testing

This paragraph delves into Mike's first-hand experience with each type of flux core wire. He starts with Lincoln wire, noting its glossy appearance but also a matte color that raises concerns about cleanliness. He then tests Vulcan wire, which has a matte gray color and is known for its consistency. Following this, Mike tries Forney wire, which comes in a sealed bag and has a shiny appearance. He also discusses the importance of the correct setup for flux core welding, emphasizing the need for electrode negative polarity and the correct wire feed speed. The paragraph includes practical tips, such as the necessity of welding at a slower speed with flux core wire and ensuring proper wire extension to minimize spatter.

10:07

🌐 Comparative Analysis of Flux Core Wires

Mike continues his comparative analysis of the flux core wires, testing the Yeswelder and Hynade wires. He notes the Yeswelder wire's vacuum-sealed packaging and shiny appearance, and shares a welding tip about the importance of 'pulling' the flux wire to avoid incorporating flux into the weld, which can cause porosity. The paragraph also touches on the forgiving nature of flux core welding when it comes to rust or dirty metal, but still recommends cleaning weld joints for optimal results. Mike then presents his initial impressions of the welding performance of each wire, highlighting the smoother operation and less spatter of certain brands. The paragraph concludes with a plan to further clean and evaluate the welds to determine the best performing wire.

15:10

🏆 Ranking and Review of Flux Core Wires

In the final paragraph, Mike ranks the flux core wires from worst to best based on his testing. He identifies the Vulcan wire as the least favorable due to its inconsistent weld bead and high spatter levels. Lincoln wire follows, being the most expensive and not performing as smoothly as others. Mike then discusses the top three wires: Forney, Yeswelder, and Hynade, which all performed well but with Forney standing out for its crisp and smooth operation. He notes the importance of machine dialing and the auto-set feature of the Hynade 140 amp machine, which contributed to the consistent performance across tests. The paragraph ends with Mike's recommendation of the top wires and a mention of a discount code for Yeswelder, as well as a note on the value and affordability of the tested wires.

Mindmap

Keywords

💡Flux Core Welding

Flux core welding is a type of arc welding process that uses a consumable tubular wire filled with flux to lay the weld. It's known for its ease of use, especially in outdoor and windy conditions, as it doesn't require shielding gas. In the video, Mike Festiva tests different flux core wires to determine their performance in terms of spatter and weld quality.

💡Spatter

Spatter refers to the small metal droplets that are expelled during the welding process. It's generally considered undesirable as it can contaminate the work area and the weld itself, leading to a less clean and less strong final product. The script discusses the varying levels of spatter produced by different flux core wires.

💡Flux Core Wire

Flux core wire is the material used in flux core welding. It's a tubular wire filled with flux which helps to protect the weld pool from atmospheric contamination and also stabilizes the arc. The video script describes a comparison of various brands of flux core wire based on their performance.

💡Hynade 140 Amp Flux Core Welder

The Hynade 140 Amp Flux Core Welder is a specific model of welding machine that Mike purchased and used in the video for testing different flux core wires. It's noted for welding smoothly and coming with a spool of flux wire that performed well in terms of spatter reduction.

💡Electrode Negative

Electrode negative is a term used to describe the polarity setup in a welding machine where the welding gun (electrode) is the negative terminal and the workpiece (welding clamp) is the positive. This is important for flux core welding as it helps to stabilize the arc and reduce spatter, as mentioned in the script.

💡Stick Out

Stick out, also known as electrode extension, is the length of the welding wire that extends beyond the contact tip of the welding gun. The script explains that a longer stick out is generally used in flux core welding compared to solid wire welding, which can affect spatter levels.

💡Slag

Slag is the non-metallic material that forms on the surface of a weld as a result of the welding process. It protects the weld pool but must be removed after welding. The script mentions the importance of slag removal and how different wires may leave varying amounts of slag.

💡Weld Puddle

The weld puddle is the pool of molten metal that is created during the welding process. Monitoring the weld puddle is crucial for controlling the weld's quality and ensuring proper fusion. The script advises watching the weld puddle closely when welding with flux core wire.

💡Travel Speed

Travel speed in welding refers to the speed at which the welder moves the welding torch along the joint. The script notes that a slower travel speed is necessary when using flux core wire compared to solid wire and shielding gas.

💡Vacuum Sealed Pouch

A vacuum sealed pouch is used to package welding wire to prevent moisture and air from affecting the wire's performance. The script mentions this packaging method as a positive feature for certain brands of flux core wire, indicating quality and preservation.

💡Clean Weld

A clean weld is one that has minimal spatter, slag, and other contaminants, resulting in a smooth, strong, and visually appealing final product. The script discusses the importance of achieving clean welds and the factors that contribute to them, such as the type of flux core wire used.

Highlights

Mike Festiva tests five different makes and brands of flux core wire to determine their quality and performance.

The Hynade 140 amp flux core welder purchased from Amazon offers a smooth welding experience and comes with high-quality flux wire.

Flux core wire is not created equally, with some producing more spatter than others.

Tips and techniques for beginners in flux core welding are provided to improve their skills.

The importance of the quality of flux core wire is highlighted, as it affects the welding process and results.

Different brands of flux core wire, including Lincoln, Vulcan, Forney, Yes Welder, and Hynade, are tested.

Flux core wire should be used with a slower travel speed compared to solid wire and shielding gas.

The significance of the polarity setup in flux core welding is explained, emphasizing the need for electrode negative polarity.

Forney wire is noted for its shiny appearance and good performance in the welding tests.

Proper stick out length is crucial in flux core welding, with a longer stick out potentially increasing spatter.

Yes Welder's vacuum-sealed pouch prevents moisture from affecting the wire quality.

The technique of 'dragging' the flux wire rather than 'pushing' it is recommended to avoid porosity in the weld.

Hynade wire, which came with the welder, impresses with its performance and consistency.

Flux core welding is more forgiving with rust or dirty metal compared to MIG welding, but cleaning is still recommended.

A comparison of the welding results before and after cleaning off the spatter and slag is presented.

The Harbor Freight wire cleans up the best with a brush, while other wires require more effort.

Final results rank the wires from worst to best, with Vulcan and Lincoln at the bottom and Forney, Yes Welder, and Hynade at the top.

The video concludes with a recommendation to keep the top three wires on hand for flux core welding.