Popping and inconsistant welds

[Qbaum]

Have had Hobart Handler 135 for about 2years now.
Somewhat new to MIG welding but enough knowlege to know someting is just not right so now I am doubting the welder.
The welder (me being the weldor) seems to be inconsistant in the welds that it produces. I can't seem to get any consistancy in the wire feed/volt setting anymore. I am using solid core with co25 gas at 20cfm.

I was welding a project the other night getting some reasonable porformance in about three inches of weld in new hot rolled angle, when in the last inch of the 4 inch weld, I started getting some puddle break up with associated popping sound.
This happend on EVERY weld that was over 3 inches in length on a four inch weld! Tried different grounds, tried higher voltage and
polarity is correct.

Yep, I think I am taking my Hobart Handler fishing except it's not comming back. Unless the fish are biting on it that is.

What to do?????????

[Ed Heimbach]

Seems to me that your regulator may be having problems, did you notice if the body of the regulator was really cold? It could be freezing, when frozen no gas will flow.

[Sberry]

Here is something to try,, a couple things actually. How good is the electrc circuit you are on? Did you change circuits or add a cord? Make sure the cord, your stinger is straight. Make sure you have good ground near your work and its a good idea to run the leads along side each other. 4. Change the tip also.

[Hobart Expert Dave]

A couple more things to look at. Could be the contact tip is heating up and constricting on the wire causing a feed problem. Have you swiched wire lately. could be a bad batch of wire, The size could be inconsitant on the diamater and causing feed problems. also could be a kink in the liner or even too tight of wire spool tension. Just a few thoughts.
Dave Evans

[Guest]

Maybe circuit board problem....thermal?

[Seldom]

Yup, something certainly is fishy with your machine and all of the answers so far are pertinent to your problem. Since you’ve ascertained the puzzle is repetitive and each time involves an identical amount (key puzzle component) of wire here’s a couple of thoughts.

First figure about how many in/min you’re using when the puzzle occurs. Disconnect you roll(s) and pull the trigger while watching your flow meter but most importantly listening to your gas flow. You should at first hear a fairly significant burst of flow then it settle will back to a consistent one. If your solenoid is screwing up you could be getting an initial flow but it could be the closing in those seconds of your weld-time.

If you find no difference and the flow is constant, move on to the whip. Screw out the tip and run the amount of wire you’ve determined equals 3” of weld. When you do this bend the wire slightly so you don’t poke yourself and allow the wire to run into your hand. This technique applies some resistance to the wire and allows you to feel any drag or rough spot. This checks the liner condition and the roll(s) tension.

If you still haven’t found the solution to this puzzle, move to the tip. Either drill out the tip to the next size wire diameter (if you have the ability to do so) or go down to the supplier and buy the next size tip and try it. It’s possible you have an undersize tip that expands very quickly to very little heat. If you’ve used the tip previously without a problem-forget the tip!

If you have the ability to do so, blow out your machine with compressed air. This can be a cause of many types of thermal (as Rocky pointed out) malfunctions in welding machines of all types if they are used or stored in dusty (metal dust is the worse) conditions.

If none of these little “self-checks” affect a positive change, either take it to a shop for checkout and repair or if you’re so inclined, take it fishing! LOL

[Hobart Expert Rock]

QBAUM...........WELCOME ABOARD.............. I WOULD LIKE TO KNOW WHAT YOUR OCV IS IN ALL 4 RANGES...........THEN WHEN YOUR MACHINE ACTS UP REMEASURE THE VOLTAGE IN THAT RANGE....... MAYBE IT IS DROPPING LOW..............ARE WE ON AN EXTENSION CORD.............AND IF SO HOW LONG IS THE EXTENSION CORD AND WHAT SIZE WIRE..............YOU WILL NEED A DC VOLT METER TO MEASURE THIS..................JUST MY .02 CENTS WORTH..................ROCK....................
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[Bobby]

how do you measure OCV? one test lead on the ground clamp and one on the wire?

[Qbaum]

Popping welds

So Far------------

I have checked the regulator, and yes it was cold so it could of been a frozen regulator.

I fan that I have just put in the shop was blowing in the area I was welding.

I noticed that when I had my back turned to the welding process the welds were greatly improved.

Now that's not to say that I was welding in a huricane, I just had a fan blowing in the general area and not right on the welding process.

I also adjusted the tension on wire feed inside the unit

Still probing!

[INTP]

A liner is cheap, and relatively easy to replace. I had trouble with my MIG where it was feeding at inconsistent speeds. You could see that the feed rate was inconsistent just by watching it (not while welding). It was the liner.

[Hobart Expert Rock]

Bobby.......Yes that is correct..........Typically on the Handler you must pull the gun trigger to see this voltage...............Rock..
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