FluxCore Thin Metal without Blow Through - Updated

In this follow up to an earlier video, David covers ideal machine settings, weld positions, and contact tip to work distance using Lincoln NR-211 self-shielding flux core wire and 16 gauge steel.

[@bartman2468]

The clear demonstration of how the voltage and feed speed affect the quality of the weld on thin material was super helpful. Great video

[@coolcat312]

I've watched dozens of videos on flux core welding over the past two months and this is the first one I've found that actually describes what wire speed and voltage settings do. I'd still like more info on how to recognize what adjustments to make to get better welds but now that I know a little more about what these settings actually change I might be able to experiment on some practice pieces to get a better handle on what is going on. Thank you!

[@thoxbui]

you can always tell a real expert by how simply and clearly he/she can explain things to you. Thank you!

[@SpaceMonkey23101]

4:24 Good job mentioning the contact tip distance/wire length. I struggled with bad welds for ages before realising that you need to have the gun tip really close to the work (5-8mm often).

[@GeneralAir]

You're absolutely right! This is an often-overlooked setting that can have a major impact on the quality of your weld.

[@armcchargues8623]

Glad to see a video by someone that knows what he's doing AND a good instructor. Excellent presentation.

[@brianmitchell9890]

This really is really helpful for someone new to flux core!

[@CTSCAPER]

Very informative and well-presented video!

[@bryanrocker5033]

Some good information. Now to related the voltage/wire speed to the standard spots on my Lincoln welder.

[@markharrisllb]

Only 536 people have seen this video, that’s a such a shame as this is really useful to newbies like myself. The only fault I can find is the level of the music when using ear buds.

[@GeneralAir]

We're glad you enjoyed the video, Mark! And thanks for the tip on the music volume.

[@pcdubya]

I'm learning and burning. Just welded up a four wheeler rack with a lincoln flux only machine, and have to kind of tap, tap, tap, instead of a long, continuous bead to keep from burning through. Works pretty good doing it that way.

[@GeneralAir]

Nice work!

[@richardoky]

I have been welding for years and the best advice you can give someone using flux core is to buy a bottle of C25 and use solid wire. I don't know anyone that has changed from welding using flux core to C25 that wasn't happy with the results espacilly with thin metal.

[@mick2d2]

Great video, thanks for taking the time to make it. Subscribed!

[@GeneralAir]

Awesome! We are glad you liked the video. Thanks for subscribing!

[@BD-ki3vv]

@general air service and supply. Can you do a video flux core welding expanded metal to 1/8 thick plate? I am having a difficult time with this using .030 wire. Everybody says set up machine for the thicker metal then let the puddle just barely spill over to the expanded metal. I am not getting consistent results with this method. Should it just be spot tacked?

[@GeneralAir]

Every situation is different, keep at it and keep watching videos. We will certainly consider a Flux Core video with expanded metal to 1/8."

[@jed2055]

Aside from the informative video, I noticed the hand shield on the gun. By the look of it, a lot of splatter has been prevented from hitting the users clothes, gloves etc.

[@davidtodd4035]

This guy is amazing

[@GeneralAir]

Thanks David. We think David is pretty cool too.

[@nmartin5551]

Great video!!! Still new, still trying, I love it but I need to improve!!! This will help!!

[@GeneralAir]

You got this!

[@andrewbrown1463]

I’m new to flux core. I’m welding 22ga sheet on a car panel repair. Lincoln Electric with 0.035” wire. My machine is set to “A” which is the lowest voltage setting. Should I also be set to a very low feed speed to avoid blow through? Polarity is currently set to clamp as + and wire feed to -. Appreciate any inputs for the best Weld.

[@GeneralAir]

We would suggest going to an .030 wire and yes, use the lowest settings you can on your machine with wire feed speed being the most important to control the heat since that is what controls amperage.

[@johnallen3555]

your bending of the weld test leaves a lot to be desired - you didnt bend the weld u turkey, you bent some distance from it. u turkey apart from the numbnuts bend test, really good video!

[@tommyd1155]

So what was the metal material you had under what you were welding on. What kept it from welding to it?

[@GeneralAir]

This was on a steel table, the settings that we had for this weld would make it impossible to make it go through the piece and into the table.

[@charlescarabott7692]

Can i weld 20 or even 22gauge with flux core? And will a mig flux core welder that has very low amp settings like 10amps make flux core welding very thin steel more possable or is voltage control more important?

[@GeneralAir]

Due to the high penetrating nature of flux-cored wire, 20 and 22 gauge would be very hard, next to impossible, to weld. The process you want is short-circuit MIG (GMAW-S).

[@jacobgreen6939]

​@@GeneralAir how about just tiny tacks.

[@ismoaulaskari3987]

@@jacobgreen6939 try tacks kzbin.info/www/bejne/n5SaeKqcbd5nj8U

[@robertghorne8607]

Stitch weld?

[@hangngoaigiare]

Very nice voice you can get work in the movie industry:)

[@Thomas-Almanza]

Never knew that the wirespeed setting also controls the amperege

[@superbee6270]

Hi what do you recoment for the beginner for a welding helmet and a brand please

[@GeneralAir]

We recommend the Viking series helmets. The 1740 (store.generalair.com/viking-1740-black-k3282-3/) is great for beginners as it a good helmet with a reasonable price point.

[@jimgam730]

So, where can I get that book?

[@GeneralAir]

You can download the book from the manufacturer website or stop by any General Air location and grab one for free.

[@robertghorne8607]

Any thoughts on sort of rusty metal to new metal. Say , floor metal on a car.

[@GeneralAir]

Rust should always be removed if possible. Rust is a very poor conductor of electricity and will prevent you from achieving a strong weld.

[@plankton3979]

Whats the minimum thickness u had tried?

[@GeneralAir]

18 gauge, I'm sure you can go thinner if you use .030 wire but Flux Core is not the best on thin material. MIG or TIG would be better.

[@larrybud]

wouldn't you be better off going uphill when vertical, to keep the slag from melting into your new pool? "gravity assist" dragging, it seems to me.

[@GeneralAir]

Yes, slag could get into the weld and MIG would be a better process for thin material, I was demonstrating that it could be done, though it is not the ideal method. Vertical up would slow you down, increase heat input, and definitely cause blow through.

[@horaciosalinas8145]

did you flux downhill ? I thought you couldn’t do that with flux

[@GeneralAir]

No, it is a bad idea to go downhill with fluxcore unless you don't care about slag inclusions and you are just trying to get the pieces to stay together. You bring up a good point, never downhill on material thicker than 3/16".

[@andiegomes2764]

Where can I get that book manual ?

[@GeneralAir]

Hi Andie, all of the Lincoln Electric manuals can be ordered or downloaded from the Lincoln website, free of charge. Here is the link, all of these manuals are listed under "welding guides" bit.ly/3jlmOba

[@TheUltimate65]

Its many types of this Flux core, some Are steelcolored , some Are coted wit Cooper , Like Rimac have , im use a type its close of the esab have, and its good too use , but Flux core its a abother way too welding ..

[@rmckayne]

Sorry, I wonder you will show real thin sheet metal , like 20 ga or 22ga. But 1/16 for me still got meat. Thanks anyways.

[@GeneralAir]

Hi Ramon, Sorry this video didn't have what you were looking for. Welding 20 or 22 gauge is a better fit for MIG or TIG, it would be very difficult to use flux core with material at that thickness.

[@leonardpearlman4017]

I know he's legit b/c he's got the MANUAL (I just printed that out!) and one of the terrifying Lincoln three hundred (five hundred?) Amp guns.... Also, this is addressing my specific situation!

[@bobd.fletcherjr4912]

👍👍👍👍👍👍👍👍👍🙋‍♂️🙋‍♂️

[@markkiser5120]

what wire size ? 30 or 35?

[@GeneralAir]

.035

[@mpcinlv]

Turn down the background music ... distracting. Great video.

[@CeeKayz0rz]

>The first thing we need to do is buy a $3,000 Miller....

[@bigdave6447]

Reminder, NR stands for Not Reverse polarity or straight in other words .

[@GeneralAir]

That is news to us! Makes sense though. Thanks for sharing.

[@bigdave6447]

@@GeneralAir thats what the Lincoln rep told me .

[@elkvis]

You didn't actually bend the weld. You only bent the metal next to the weld.

[@kjdiamondsword3520]

That is the point. If the weld had been weaker than the base plate it would have bent at the weld seam, but because it did not bend at the weld seam it can be inferred that the weld was stronger than the base metal.

[@GeneralAir]

KJDiamondSword is exactly right!

[@GeneralAir]

Thanks for watching!

[@user-vm6mv8il6s]

this is not thin , thin is tin can , 0.3mm or 0.010 inch , try that with cheap machines which has one knob for both amp and wire speed so these setting are useless to most of us useing budget stuff

[@andycuellar8125]

To weld thin metal with flux core i just tack weld all the way like if i was doing a strait bead but tacked all the way. The reason for attacking instead of doing a straight beat is to allow the metal to cool down the only reason why welders blow through thin sheet metal is because too much heat has penetrated the metal. If you stick weld or flux core it is best to simply tack all the way to the bottom to allow for adequate penetration ✅

[@Colonelcheeser]

@@andycuellar8125what happens if it always burns through?

[@mattwest5647]

Turn the music down or ditch it entirely, it's very difficult to concentrate on what you're saying.

[@rinklestiltskin]

Thin? Ha!

[@jeffjoestar4245]

of course your weld survived the bend test, you bent an inch away from it

[@martymcfly3986]

run a 22 or 24 gauge, 16 gauge any idiot can do

[@davidlee9299]

Not everyone can weld that and that is the reason some of us watched the video... And I think he said that flux core is not proper choice for that guage of metal, which taught me something about my project which is about what I am working with...

[@allgasnobrakes4979]

This is not thin metal show us on real sheet metal

[@georgesimpson3113]

Oh goodie. Another music video. Turn the crap off or at least way down. Do you want to show people welding or music? Choose.