Basic Flux Cored Welding on Square Tubing

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• Basic Flux Cored Weldi...
In this video I am going to be discussing Basic Flux Cored Welding on Square Tubing by introducing you to the types of welds involved, and demonstrating how they are produced.
I hope you will enjoy the video, and if so, please hit the "Like" button after watching. Also, don't forget to subscribe to my KZbin Channel so you can be updated whenever I post a new video.
Take Care,
Dan

[@BriansLegitEdits]

Wow this is the best video for a beginner to watch regarding flux core. I learned so many things so fast from this. Using Lincoln multi pass is crucial too. Thank you, time to complete my project, thanks!

[@WeldFever]

Thank you. I appreciate it and glad you picked up some info - Dan

[@johnorchard6158]

Dan, thank you for your patience in explaining the technique so carefully for us new guys. The wire speed vs amp comment, did not know. All the best for new year. JO London Ontario

[@Broxty]

I absolutely love flux core, thanks for sharing this!

[@docswoodden1363]

Thanks for taking the time to show this video. I'm a wood worker and it shows in my welding ability lol Doc

[@WeldFever]

Doc's Wood Den You're welcome and I am actually a converted woodworker myself, so hang in there!

[@Officer235]

Dan thank you for this video. I have a porch railing repair project where I have to cut out and replace rusted out sections. I was getting a lot of burn through but you explained how to avoid that. So one major headache solved. By the way the sections are 1" square similar to what you used in this video but yours looked like 1 1/4" square. Once this rain stops I look forward to getting out there and working on this project some more. Thanks Dan you really came to help on this one!

[@callapygian]

Wow learned something very useful! (The MP meaning) thanks

[@cjcashville4539]

hey this helped alot i just started welding school this monday

[@NOBOX7]

thanks for showing us the wire specs friend the MP thing really took me back i didnt know that , things like that are what we need to know and i have never herd of such a thing

[@WeldFever]

+NOBOX7 I am glad that it helped you and thanks for the comment.

[@Michael_00001]

That was key!

[@joebriggs9599]

Thanks learning a lot from you just started welding only using flux core now. I can only weld outside.

[@coreymcdonald2392]

hot damn nonone ever told me to raise the amp via wire feed speed....now i know why i was messing up.. this no one told me that the voltage dial was only for arc force like the dig is to stick welding .. you may have just saved me from failing this test in the morning i reall y need the job, thanks alot so much alot alot alot lol

[@WeldFever]

+corey mcdonald You are very welcome. Keep in mind, the voltage controls arc length and not necessarily arc force, or dig. A higher voltage will produce a higher arc and a wider bead. The reverse is true of a lower voltage. Good luck with the job and let me know how it goes.

[@coreymcdonald2392]

i keep failing i try so hard

[@scrapman9148]

+corey mcdonald in welding going slower is usually better. you get the most penetration right before you burn through.

[@coreymcdonald2392]

Thanks I'm slowing down now in Oakland CA welding war craft

[@waldan1701]

This is helpful. I bought a cheap Harbor Freight Flux Core welder for $89 and have tried to teach myself. I am having a hard time with my travel speed. I either go to slow and blow holes in the metal or to fast and don't leave enough weld in the joint.

[@WeldFever]

+waldan1701 Try counting, or welding to the rhythm of your favorite song. That helps keep your travel speed consistent.

[@waldan1701]

Thanks, I never thought of that. I will try it.

[@tomherd4179]

You mentioned changing the wire speed, but I may have missed the direction to take. My guess would be to lower the speed to increase the heat, thus, putting in less metal to absorb heat. Is this correct? Good videos. I found a sign that said "Danger - I Did All The Welding Myself" I like it. Tom

[@nat15.9]

Any suggestion for Current and Voltage settings on such a thin metal welding?

[@WeldFever]

Sorry for the late response. You need to start with a lower wire feed speed first. One that matches the thickness of the material you are welding. Once you have found it, you then need to match the voltage to the wire speed for a smooth weld. Check this link for more info on settings: ch-delivery.lincolnelectric.com/api/public/content/5b1a00933782415e98e56639deb63f45?v=405651b4

[@roccit]

Newbie here. I assume you're able to form an arc without having your ground on the work piece because you have it clamped to the metal table you're using. If I were to use a small metal piece (need to be very mobile) for this what is the thinnest stock I could/should use for a mini table?

[@Michael_00001]

I've done it on a sheet of metal no thicker than about 1/8th of an inch.

[@howlingwolf3978]

Thanks for the info on wire

[@WeldFever]

Michael Garewal Certainly, and thank you for saying so.

[@johnwadsworth7086]

thx I learned more about flux core

[@MOMIA918]

What are your settings on the welder..for some reason my lincoln 140 burns through my square tubing..thank u

[@teddekker3383]

WOW - again I have learned something NEW !! MP for multi-pass ! I have a new roll of flux core, listed as "ALLOY: E71T-GS" and upon checking it is listed as Single Pass !! Well that's no good for a Cocky Shit mig welder like me LOL 😂 I will need several coats of weld (after each clean that is) to make things stick a bit better ha hah Thanking you again WeldFever - I'm buying a roll of E71T-11, you've saved my bacon 🥓 👍 Ted

[@WeldFever]

Glad you found it helpful and thanks for the nice comments.

[@thatguythatdoesstuff7448]

Hey Dan, can you tell us what the name of the contact tip guard is? Or where to purchase? I'm searching on google and USA Weld, and I cannot find it. Thanks.

[@Deerslyr81]

What's the best/cheapest no gas welder to get? I want to learn to weld but don't know where to start.

[@bboyer88]

my honest advice is start with a stick welder, once you master that a MIG is easy to run. and go with one from Harbor Freight. cheap and easy.

[@Michael_00001]

I got a Lincoln 125 machine from my local Lowe's. I don't remember how much it was but it wasn't too expensive.

[@martinwalters1954]

I'm just getting into MIG/Fluxcore welding so forgive my ignorance, but I'm curious about the gun you are using. Most videos show a gun tip that seems overly large, but yours is almost pencil point shaped. Can you tell me the brand of machine you are using, or gun or tip, whatever? The large types I've seen really turn me off to this type welding, but now that I've seen the type you are using, I really want to get into Mig/Flux core welding. Btw..thanks for the tips.

[@WeldFever]

+Martin Walters Since I am flux cored welding, I am using a special flux cored nozzle, since there is no shielding gas needed. If I were to switch back to MIG, then I would have to put the MIG nozzle you described back on. The flux cored nozzles can be purchased at welder supply stores and I have even seen them at big box hardware stores.

[@MatthewCuba]

Hi there. Good info. Can you explain why the "single pass" wire cannot have a second pass? This confuses me a bit. I understand that with FCAW one needs to clean the flux between passes. Just not sure I understand what it is about the "single pass" wire that makes the welds fail with multiple passes. Thanks! I enjoy your videos.

[@WeldFever]

+Matthew Cuba Yes, these single pass wires rely on admixture or dilution with the base metal to produce the weld deposit. If used for multi pass, then after a few passes you would begin to have an all filler or all weld metal deposit, which could result in an undesirable weld bead and cracking, due to the resulting alloy content of the weld bead. Hope that helps.

[@AnythingVG]

WeldFever Hi, I just purchased a lincoln power mig 210mp. Since I didn't purchase a gas bottle yet, I wanted to use the supplied flux core wire. When I originally turned on the machine, I laid a couple practise beads, and the arc was nice and smooth, etc. Since then, when I am trying to weld, the wire keeps like bouncing off the metal while welding, like it keeps on bouncing back. Do i need to up the voltage? Up the wire speed? I've tried adjusting, but just can't get it right. Thanks!

[@WeldFever]

AnythingVG What you need to do is clip off the end of the wire before every new weld. This is a common problem, because most don't realize this is the correct way to do it. When you start up again with a dirty, slaggy, burnt end, it usually won't start and bounce off, because there's too much junk on it to complete a circuit. Also, make sure your metal is clean, and you have a good ground/work connection. Next week I'm doing MIG/FLUX troubleshooting, so stay tuned for that!

[@AnythingVG]

WeldFever Thank you very much for your reply. I actually was welding on something different, so I adjusted my settings accordingly. I believe I was welding with settings on 18ga or so, and with the slower pace, it was actually having no issues at all. It's also a dual voltage machine, and I am running on 120v on a 20a breaker, so that may be a contribution to the problems!

[@criticalthinkingwjake]

What welder are you using?

[@mitch60609]

Hi can you tell us the limit on max length extension cord that ca be used for a 120 or 160 flux core. Thanks. Some of my projects are not limited near my wall socket.

[@Mr99dm]

I've used a 110 machine on 100' cord, just make sure its a heavier wire, like 12/2.

[@sammysnead9670]

Dan, when setting up to weld two pieces of different thickness metals together, i.e. 1/4" to 3/16", which thickness do I select on the chart inside my welder? I don't recall hearing this anywhere. Thanks, and keep up the videos!

[@WeldFever]

+Sammy Snead Choose the thicker for the setting. Lay on the thicker material longer, and sweep over to the thinner so as not to burn through. You will get the best fusion this way.

[@sammysnead9670]

+WeldFever Thanks Dan!

[@MidGAOutdoor]

what kind of wire wheel is that? do you have a video on capping the tubing?

[@WeldFever]

+MidGAOutdoor Assuming you are referring to the wire wheel I use for cleaning, it is a mild steel, branded, wire wheel for a 4 1/2 inch angle grinder. I use the Harbor Freight ones, as they are reasonably priced , and hold up when used correctly.

[@Condishun1]

Im curious is it not necessary to prep the joints before welding?

[@WeldFever]

***** What specific prep are you referring to?

[@mikehenry4743]

Good videos, thanks!

[@dogbyte555]

This is good information, man. Thanks

[@WeldFever]

dogbyte555 You're very welcome and I'm glad you find it useful!

[@lexoaz]

Welding wrought iron I have mig/flux welder what method would you recommend thx

[@WeldFever]

lexoaz If you're welding outside with winds over 5 miles per hour, then flux cored.

[@1999Shortstuff]

Are you saying that the 5/16" designation on the wheel means that you cannot stack the weld bead higher than 5/16" (with multiple passes)?

[@WeldFever]

+1999Shortstuff That is correct and it is not me saying it, it is the manufacturer. Here is what Lincoln Electric has to say about it: "Certain FCAW-S electrodes are limited to a maximum steel plate thickness in which they can be used. If used with plate thicknesses beyond these recommended limits, then the cooling rate of the weld metal could be faster than desired, due to the thermal conductivity or weld quenching effect of the thicker plate. This in turn could potentially create an undesirable microstructure in the weld metal, from which weld cracking issues could potentially result. Electrodes with plate thickness limitations are listed in the table directly below." Myers, T. (2015) Innershield wire, FCAW-S Welding Guide, Lincoln Electric Co. www.lincolnelectric.com

[@rawritjon]

with flux core do you weld with a cursive E?

[@rolyat13013]

I could not find MP on the Lincoln wire.What else should I look for?

[@WeldFever]

rolyat13013 Are you in the U.S. and is it Lincoln 211 flux cored wire you are looking at? if so, look at the fine print on the label that will indicate if it is a multi pass flux cored wire, or not.

[@rolyat13013]

Thank you! I never new that, now I know what to look for.

[@painhour]

thanks for the info.

[@kentharris4303]

How much weight will those T's you welded hold? I was going to use 2 inch square steel tubing with an internal diameter of 1.76.(.12 thick wall) I am building a work bench out of 2X2 Spruce Pine that was left over from another project. The actual diameter is 1.437" square. I want to make the bench portable so would drill a hole through the Metal tubing and 2X2s and bolt it down. When I am finished using the bench I could pull the bolts out and could store the table flat. I used to solder circuit boards. It looks similar with the exception of the safety gear.

[@lin018]

What's the wire speed and voltage used ? Thanks

[@irishlush364]

I just welded 14 gauge square tubing with my titanium on D 4.5 worked great

[@mckinleylandscaping5347]

I like your videos! Will definitely put one of your stickers on my welder!.....If you have a sticker giveaway!!!

[@RickRabjohn]

Nice! I never new about Single vs. Multi pass wire :-( As it turns out, I have been making multi passes with single pass wire in making my welding table Ugh!. So what do you think happens over time - can you elaborate a little?

[@WeldFever]

Rick Rabjohn Great question! According to Lincoln Electric, single pass (FCAW-S) electrodes rely on admixture or dilution with the base metal to produce the weld deposit and if used for multi-pass welds, after the first few passes you would begin to have all filler, or all weld metal deposit. The resulting alloy content of the weld bead could be undesirable and cracking could potentially result. Sorry for the bad news.

[@crcdesign9886]

I have HORRIBLE luck/skill with Flux core welding.. I have a 170amp HF Mig machine. welding with Argon Mix and solid wire works great. I can produce very nice welds. HOWEVER, when I switch over to flux core wire if I run out of gas it looks terrible.. The weld balls literally jump off the piece I'm trying to weld. And yes I do change the polarity inside the machine. Is there a trick to flux core welding or is it really that hard compared to welding with solid wire and gas?

[@WeldFever]

Mobile AutoMD There really is no trick. Not changing polarity is usually the culprit, but since you say you have that covered, I would next look into the wire you are using. Make sure it is a quality wire, and that it has not become wet, rusty, and is not very old. They usually have a shelf life of about a year or so. Make sure your stickout is around 1/2" (more than you would with MIG), and that your base metal is clean. If all that does't help, send me another message with a few more details and we'll keep at it. Good Luck!

[@WeldFever]

WeldFever Another note on sickout (more properly known as contact tip to work distance CTWD) for certain flux cored wires it is recommended that you have a 3/4" to 1" CTWD, but I find that 1/2" works well with this smaller nr-211. Sometimes I wonder off as far as 3/4" with no problems.

[@crcdesign9886]

Well sir you have nailed the problem I suspect... the wire I have has been laying open in my work van for 2 year AND it's the cheap stuff that comes with the welder. The solid wire didn't seem to mind that as much though.

[@WeldFever]

Mobile AutoMD Well how about that. I hope that solves your problem. Good luck and let me know how it turns out when you get some new wire.

[@theElderberryFarmer]

Mobile AutoMD I also have a HF MIG 170, and I promise you that the issue is the junk flux-core wire it came with. Toss that stuff and get a roll of good quality flux core wire and you will be much MUCH happier.

[@xjmachine2503]

can i use flux core to weld spring perches on an axle? I have read so many different things online, some say they use it with .035 wire to do that type of work on their jeeps, and others say not to. it seems to be a 50/50 draw, any advice would be greatly appreciated.

[@WeldFever]

+xjmachine Generally, flux cored welding is just as acceptable as any other process of welding with one exception. You must know the thickness limitations of certain flux cored wires. For example, the wire I use for general small fab and repair is Lincoln, NR-211-MP, in .035, and it is only meant to weld a maximum plate thickness of 5/16." So, if your project's metal thickness is greater than that, you could not use this type of wire and would need to look at another type of flux cored wire, which may or may not work for you. Good luck.

[@السيدعليالقصاب]

bro, is it flux core means " no need for gas " , gas less?? also can we weld stainless steel by it?

[@Mindventmofficial]

uhhh what the hell do YOU MEAN GAS LESS == NO GAS Same crap why try to even correct something that he said correctly Jeez

[@trevorkannady792]

The welds are really concaved. You gotta let your weld pool build up more about the size of a penny is a average size, then keep it constant.

[@WeldFever]

+trevor kannady Unfortunately, sometimes the angle and the light play tricks on the appearance of the weld on camera. Believe it or not, the welds were actually flat to a bit convex, though I can see how you would believe otherwise. I try to lay down fillet welds so that the leg size is as close to the thickness of the material as possible. This cuts down on the heat affected zone, which as I am sure you know, is the weakest part of any part welded. Thanks for the comment.

[@clapadamclap]

need some anti spatter spray there mate..