MIG Question: Dropping from 0.035" Wire to 0.023" - Hot Rod Forum : Hotrodders Bulletin Board
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Old 01-02-2007, 02:55 PM
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MIG Question: Dropping from 0.035" Wire to 0.023"

Santa recently gave me the hardware I needed to convert my Millermatic 250 from a 0.035" wire setup to 0.023". After putting it all in, I thought the only setting changes I'd need would be to drop the voltage and wire speed. Unfortunately, as soon as I lower the voltage, my weld starts popping and the work area is covered with dingleberries. Adjusting my wire-speed accordingly, even on down to "zero", doesn't seem to be helping.

When I turned the voltage and speed back up to what I used with 0.035", then my 0.023" welds are fine. Still, this doesn't follow my understanding of what's necessary when changing to smaller wire. I should be lowering the voltage and speed somewhat - right?

Am I doing something wrong?

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Old 01-02-2007, 04:19 PM
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No, you still need to run as was before...but with the smaller wire, less current will be at the weld point, due to higher resistance in the smaller diameter wire.Another thing you should do (assuming your 250 is like my Vintage) is make sure you're on the low range...on mine there's a lever/switch insode by the wirefeeder, IIRC.
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Old 01-02-2007, 04:55 PM
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The only thing I change on mine when dropping down to a smaller wire size is I have to increase the wirespeed a little .
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Old 01-02-2007, 05:45 PM
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Mig welder settings

Most of the time when you get a lot of splatter from a wire welder it is caused by either too much heat, or not enough wire, or both. A lot of time when turning the voltage down to a very low setting does not seem to make much difference it is because either the wire is slipping at the drive wheels or there is too much tension on the spring that keeps the wire spool from free wheeling.Also you might check the condition of the liner inside the gun if you didn't replace it with a new .023 liner. It could be dirty and need blowing out with compressed air. If you have already checked everything out and it seems to be ok. You will have to experiment with a varity of settings to get it to weld right. the settings will be quite a bit different with the smaller wire.If the wire isn't binding up or dragging then it should weld just a good as .030 or .035 once you figure out the correct settings.
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Old 01-03-2007, 12:23 PM
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If you still have the books that came with your welder, you will find a chart that gives the speed and heat to use with the various sizes of wire and material thickness. Possibly it may be on the spool cover. If you don't, you can download it off Millers website. As these are developed for different machines, the proper chart for your welder will be very accurate needing only very small changes to allow for variations in one model.
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Old 01-03-2007, 02:48 PM
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welding with .023 wire

hi,if youre welding with .023 wire,(no flux) you need the gas setup. without it the welds will look like crap,and will have holes in the welds. i have a lincoln 155,and using the gas setup,i can tack weld sheet metal,(at setting A)(heat) and speed #2,then finish weld at A (heat) setting and #7 wire speed. if you dont turn the gas on,the welds will look bad,and will have holes in the weld....im Boatbob2
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Old 01-03-2007, 02:49 PM
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welding with .023 wire

hi,if youre welding with .023 wire,(no flux) you need the gas setup. without it the welds will look like crap,and will have holes in the welds. i have a lincoln 155,and using the gas setup,i can tack weld sheet metal,(at setting A)(heat) and speed #2,then finish weld at A (heat) setting and #7 wire speed. if you dont turn the gas on,the welds will look bad,and will have holes in the weld.... also you have to change the polarity on the gas leads.im Boatbob2
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