Ball end wire

[Sundown]

I have a HH135 and have mostly been using .030 and .035 flux core and have had no problems (other that I'm at the front end of the learning curve with this welding). A few days ago my son asked me to do some welding for him, since the medal was 18 ga. I got some .023 solid wire to use (new 2# roll from Weld-it). At the end of every pass I ended up with a small ball (very hot one) on the end of the wire. I seem to remember seeing something on the old format about this but a search proved fruitless. Details are DECP, ER70S6 .023 wire, .024 Hobart tip, C25 gas pressure at 20lb, Voltage at 1, feed at 20, stickout at 1/4". I checked everything I can think of, and converted back to .035 flux core and did some 16GA with no problems. If anyone has any ideas I really could use the help. Thanks in advance...

George

[ZACHV]

I get this also some times. Seems like I get it when I have too much stickout at the end of a bead.

[Hobart Expert Dave]

ZACHV is correct the stickout at the end of the weld can cause this. What you are more than likly doing is pulling away from your weld at the end before the gun trigger is released. This will cause the wire to feed a split sec longer and the voltage to kick up causing the ball on the end of the wire. Try releasing the trigger on the gun and stay the same distance you were welding a second before you bring the gun back. The problem being is if you weld a very tight arc length then the wire just might freeze in the weld puddle. Not always the case but it could happen.
Thanks
Dave Evans

[Sundown]

Ball End Wire

Just like my wife always says, I'm outta control. Sounds like that might just be whats happening. I'll check it out this weekend and see. Thanks Guys for the help.

[Guest]

I queried a Hobart engineer, about this, as I was having the same problem....this is what he said:

"Q:I am ending a weld with a ball on the end of the wire...is it parameter or gas problem?

A:Yes, you will have a ball at the end of the wire. In a small unit
like this, it is difficult to add a "wire sharpening circuit" or adjustable run-in / burnback speed like more expensive industrial units.
Some welders cut the ball off each time if the ball causes too harsh of a start."

In other words, it's normal.

[Arbo]

The thugs at the prison where I work use that ball on the end of the wire to make ear rings. They love it! And...we officers have competitions to see how many we can collect (confiscate) during a day.

[Hobart Expert Rock]

SUNDOWN...........ROCKY D IS CORRECT..........LARGER MILLER VERSION MACHINES HAVE THE WIRE SHARPENING CIRCUIT IN THEM TO KEEP THE BALL OF THE END OF THE WIRE AT A MINIMUM.....HAS TO DO WITH AN RESISTOR CAPACITOR NETWORK THAT PINCHES THE VOLTAGE RIGHT OFF .003 OF A SECOND AFTER GUN TRIGGER IS RELEASED........SOME OF THOSE CIRCUITS ARE ADJUSTABLE I.E. A POT IN THEM TO ADJUST TO YOUR PARAMETERS. CONSIDERABLEY MORE TO IT THAN WHAT I JUST EXPLAINED BUT YOU GET THE IDEA...........THERE ARE THINGS YOU CAN DO TO DECREASE....... PRACTICE DIFFERENT TECHNIQUES AND LET US KNOW WHAT THE TECHNIQUE WORKED BEST........ THANKS...........................ROCK............. .....
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[Sundown]

Ball end wire

Thanks Guys, I will practice as much as possible, if anything seems to help I'll be sure to post. In the meantime my 12 year old want me to make ear rings for her. Thanks much...