Wire getting stuck

[Carterkelly32]

I have a millermatic 215 that I’m using gasless. I’m welding mild steel to galvanized metal studs and lately I’ve been running into the issue of my wire getting stuck in the tip. I’m using .03 wire and tip. What seems to be happening is that before the wire goes through the tip, it is turning black and getting small bubbles on it as if it’s getting hot. I’ve checked everything I can think of including changing tips, replacing the liner, changing wire speed, volts, and loosening/tightening the rollers, moving further away when I am welding, however nothing seems to work. Does anyone know what is causing this??

 

[Tom O]

Does it bird nest? Does it feed freely? The wire might be crossing itself as it unwinds.

 

[Carterkelly32]

Picture of wire, must be pulled through tip with pliers

 

[Carterkelly32]

Does it bird nest? Does it feed freely? The wire might be crossing itself as it unwindi

It does feed freely until it reaches the tip

 

[Carterkelly32]

It does feed freely until it reaches the tip

It will feed through like normal and even weld like normal but it has been getting caught very frequently and I’m doing a lot of welds which is really bringing down production and quality of welds

 

[bourbon]

Too low a wire speed?

 

[500e]

Wire looks as if it has Galv / zink contamination, have you tried a bigger tip or a No drill to give more clearance

 

[gaz1]

check your tip liner if it has one and also unscrew your cover as its kinda a little dirty and check for earthing between the shroud and the internal tip if that gets earthed it can cause issues of burning if the shroud touches the inner tubing

silly blobs of weld can get stuck between the shroud and inner feed

you can check with the torch liner easily enough just take off the tip and feed the wire

the next part is try to screw your tip down the wire any dirt on that wire and it will show as you slide down that tip as it should slide down easily with dirt on your wire it will jam up for fun ( wire cleaner )

also try another tip to make sure that your tip is not at fault

 

[Carterkelly32]

Wire looks as if it has Galv / zink contamination, have you tried a bigger tip or a No drill to give more clearance

By no drill do you mean just removing the smaller tip completely?

 

[Mark 2]

0.3 wire?
Your tip should be larger than the wire diameter.

 

[Islander71]

I was mig welding a galvanised trailer the other day and amazed how quickly the nozzle shroud was filling with slag, presumably from the zinc. If i kept clearing it all was fine.

 

[chip]

Have you got the correct polarity, as in earth to positive.

 

[prepman]

I have a millermatic 215 that I’m using gasless. I’m welding mild steel to galvanized metal studs and lately I’ve been running into the issue of my wire getting stuck in the tip. I’m using .03 wire and tip. What seems to be happening is that before the wire goes through the tip, it is turning black and getting small bubbles on it as if it’s getting hot. I’ve checked everything I can think of including changing tips, replacing the liner, changing wire speed, volts, and loosening/tightening the rollers, moving further away when I am welding, however nothing seems to work. Does anyone know what is causing this??

A long shot....have you got the correct polarity for gasless? Sorry I was beaten to it.

 

[Carterkelly32]

Thanks for the assistance, but I just ended up saying to hell with it and am now doing stick on it

 

[500e]

By no drill do you mean just removing the smaller tip completely?

A No or letter drill can go up in size by small increments, just give wire a fraction more clearance.
Do not remove tip

 

[Erie Fred]

By no drill do you mean just removing the smaller tip completely?

No = "Number Drill"

 

[Seadog]

Usually shown as "No." or



Abbreviation of the Latim 'numero' which means 'number'.

 

[8ob]

View attachment 454917
Picture of wire, must be pulled through tip with pliers

Either the shroud is too short or the tip is too long, at a guess I would say the tips cooking.

Bob

 

[aesmith]

Gasless, can't he just remove the shroud.