All things welding

[sab]

Have you changed anything on the gun recently, like the shroud or the contact tip? I think I remember @hosejockey61 having some issues due to a change in contact tip length that caused turbulence in the gas flow. I tried to find that post, but either I'm mis-remembering, Google isn't finding it, or both.

Edited to add: I wasn't mis-remembering. Here's the post:

Post in thread 'All things welding'

Feb 4, 2025

Blue flame means it's oxidizing somewhere. Check all your gas connections & hoses for leaks using soapy water in a spray bottle. Do you have a picture of the bad weld?

So I thought it was my gas fitting to my tank as I had a slight leak there. Fixed it and no go.

Welding has been hit and miss enough to drive me crazy. I turned the gas up to help overcome the issue. Still intermittent.

Then I remember changing nozzles out a little while back. After struggling, I went through everything with a fine tooth comb. I remember comparing nozzles and they are the same length. What I...

• hosejockey61

• 

 

[tworley]

That's most definitely a shielding gas issue. Check for leaks or obstructions along the entire line from the bottle all the way to the end of the nozzle. The leak could also be inside the machine.

Could also be that the gas is getting blown away by a fan or something like that

No fan or open doors, I can check the hose though. Using soapy water there are no bubbles at any of the connection points.

Have you changed anything on the gun recently, like the shroud or the contact tip? I think I remember @hosejockey61 having some issues due to a change in contact tip length that caused turbulence in the gas flow. I tried to find that post, but either I'm mis-remembering, Google isn't finding it, or both.

Edited to add: I wasn't mis-remembering. Here's the post:

Post in thread 'All things welding'

Feb 4, 2025

Blue flame means it's oxidizing somewhere. Check all your gas connections & hoses for leaks using soapy water in a spray bottle. Do you have a picture of the bad weld?

So I thought it was my gas fitting to my tank as I had a slight leak there. Fixed it and no go.

Welding has been hit and miss enough to drive me crazy. I turned the gas up to help overcome the issue. Still intermittent.

Then I remember changing nozzles out a little while back. After struggling, I went through everything with a fine tooth comb. I remember comparing nozzles and they are the same length. What I...

• hosejockey61

• 

I remember that too. Nothing changed, same tip and nozzle ive been using but I did take a look at the tip which might be a bit dirty and the cause...

Ill take a wire brush to it tomorrow and see if it helps. Or just replace it entirely, I have a box of tips

 

[Rickyd]

No fan or open doors, I can check the hose though. Using soapy water there are no bubbles at any of the connection points.



I remember that too. Nothing changed, same tip and nozzle ive been using but I did take a look at the tip which might be a bit dirty and the cause...

View attachment 650278

Ill take a wire brush to it tomorrow and see if it helps. Or just replace it entirely, I have a box of tips

Are the gas ports at the tip blocked? Take the collar off and make sure there is nice strong flow

 

[tworley]

Are the gas ports at the tip blocked? Take the collar off and make sure there is nice strong flow

Not completely, but there is quite a bit of buildup.

 

[Woodrow]

Not completely, but there is quite a bit of buildup.

It has to be a shielding gas issue of some sort, not that my opinion is too helpful. The last time I saw something like that, I forgot to turn the gas on.

 

[AirborneTexasRanger]

Replacing the tip could help, have you tried increasing the flow to 20 cfm? Also you could get a flow tester for $9 to verify your getting the correct flow rate at the nozzle.

https://ebay.us/m/llNbJr gas flow tester $9
Undo the wire tensioner so it's not feeding wire. Put the tester on your nozzle pointing straight up & squeeze the trigger. The number on the tester should match the one on the flow meter. If not, then there's some sort of obstruction.

 

[tworley]

So, the issue ended up being the gun connection not fully seated, which let gas escape.

 

[hosejockey61]

So, the issue ended up being the gun connection not fully seated, which let gas escape.

View attachment 650776

The electrical connection at the welder?

 

[tworley]

The electrical connection at the welder?

Nope, where the hose of the gun pushes into the welder.

 

[AirborneTexasRanger]

So, the issue ended up being the gun connection not fully seated, which let gas escape.

View attachment 650776

Good to hear it was a simple fix

 

[lBasket]

A non-issue for us flux core guys

 

[hosejockey61]

A non-issue for us flux core guys

Damn good idea! Weld that U-joint back together!