Greatly mysterious success.

[J Tiers]

It's been a year plus since working with mig in class. And I only used flux core one time for an hour or so. Hated the spattery smoking mess.

So today, I have to do some welding at work, and there is the flux core unit, a 120V POS, sitting there ready. Just a few inches of bead to weld together some pieces of 1/8" wall x 1.5" square tube.

No amperage setting, at least nothing with any pretence of current markings, so I leave it where the last guy had it, who was doing the same type welding, but wasn't in today.

So..... Huge surprise. Not only did I get a quite decent bead (no pics, they were in a hurry and painted it just as soon as it cooled off), but I saw the pool pretty clearly, and was able to see and weld up a substantial gap that had to be filled at one place.

I don't think I ever did that well nor saw what was going on that clearly using the big Miller monsters at the class. Shocked me....... maybe the little POS with a new roll of Home Despot (or whatever) flux core wire isn't that much of a POS.

Or maybe I actually learned something and was able to use the POS. Dunno.

[radkins]

Of course all flux core wire is not created equally, try some Lincoln NR211 you might be pleasantly surprised!

[J Tiers]

Well I was already pleasantly surprised, so a bit more can't hurt.....

The flux core wire at the class gave a nasty thick slag layer that resisted coming off.

The wire at work, whatever it was, gave a thinner layer that came off nicely with a wire brush, if hit before it got cold.... generally as soon as it was frozen and no longer glowing after finishing the bead..... the slag at a distance (an inch or so) was a tan sort of powdery stuff.

Maybe that is recognizable, maybe not.

And, maybe the nature of the weld helped.... it had somewhat of a "V" due to the rounded corner of one piece of tube, against the butt of the crosspiece. But nothing like a sharp inside corner which might confine the flux and maybe cook it to a more resistant coating, I just needed to weld the sides in the flat.

I was also pleased that it did not seem to spatter badly. I got a little bit, that I put down to excess stickout (bad habits returning).

All this relative niceness from a little POS 110V welder with no calibrated settings, and using flux-core. As I said, I was shocked.

[Bob Ford]

I use a Lincoln 140sp 120 volt and mostly NR211. It is great for the small things, less than 3/16s. Slightly rusted or galvanized. Lots of 1/2 and 3/4 EMT + strut. I have welded 3/8, but you need to v groove and run stringers making sure you burn each in and tied together. Lot easier to use 1/8 stick. If the machine was bought in HD there is a good chance it has NR211 look on side of spool. The characteristics you describe sounds similar.

Bob

[radkins]

There are several decent, I hesitate to say "good" when it comes to flux core, wires out there but the Lincoln 211 is one of the best and at a good price. Get everything set just right and the slag will almost fall off by itself plus it will bridge a gap better than most, the stuff almost makes flux core a good way to weld.

[Highpower]

I keep my little 120V Miller 140 loaded with flux core all the time for when I have to venture outside in the breeze or do a road trip. I would hate to be without it now after having to drag everything home and inside to use my larger 185 before I got the portable machine.