Flux Core Welding

[White Lincoln]

As a newbie with MIG welding, I had a question or two.

When welding with my cheap little Harbor Freight welder, do I use steel wire to weld exhaust or can I use aluminum wire? I didn't even think about it when I bought it. I just told the guy, "I need to weld with a MIG and anything but copper" and he handed me an aluminum reel.

My weld is non-existent yet as I have never tried MiG welding. I just have blobs of metal all over the weld area and nothing on the actual stuff I am welding (laughing my ass off as I kept expecting something different). I did oxy/ acetylene years back, but this is different.

 

[White Lincoln]

Never mind. It's obvious the guy that helped me at the store did not know anything about welding. Off to get some mild steel wire.

 

[racecougar]

If you're using a cheap HF welder, chances are it's flux core only. If you don't have a tank connected to it (like C25), it's not MIG. You'll need flux core wire.

 

[White Lincoln]

If you're using a cheap HF welder, chances are it's flux core only. If you don't have a tank connected to it (like C25), it's not MIG. You'll need flux core wire.

Yep, no gas, flux core welder needs steel wire (for steel) and flux core wire. Expensive! Learning as I go.

Just got back from Harbor Freight with the right wire this time. they have a big chart on the wall above the wire that tells you what kind of wire to get. That helped.

 

[XR7-4.6]

I’m no welder but one of the biggest issues I’m aware of with cheaper flux core welders is blowing right through thin steel, which makes them pretty useless for body and exhaust work.

 

[Zep5.0]

Good on you for taking the leap to learn. I wish I had the time and more importantly, space.

 

[MadMikeyL]

If you are just starting to learn, I strongly recommend getting an actual MIG welder with a gas tank instead of the flux core. Flux core is fine in a pinch, but the welds are always messy with lots of slag and spatter, and it is hard to control when welding thinner metal. If you already know how to weld, a flux core is better than nothing, but if you are trying to learn, you’ll likely get discouraged by the flux core.

 

[White Lincoln]

Frack... I had photos! I really had the photos of my first welds!!! But when I went to turn on my PC, nothing. The drive took a dump. Luckily, I kept my Win 10 drive and plugged that in. But my photos are not understood by windows 10 (HEIC) so I am having to download VLC to open them and put them in here.

Thanks Zep. I looked at it this way: I could pay someone to weld my joints on my exhaust, pay someone to make me a hitch and do some other stuff all for the huge unjustified price of hundreds of dollars. F-it... it's time to man up, buy a beginners welder and equipment and I will not only have fixed my stuff, I will have learned a trade that is invaluable when the wife wants a new steel coffee table with a glass top for the porch...

And Mr. Mikey... I contemplated what to do for some time. I have been wanting to get a small oxy / acetylene welder and tanks and pic up where I left off, but the damn price was just nuts. I would rather use gas, it is clean and strong unlike MiG that is messy and strong, for what its worth.

 

[White Lincoln]

Got new pics:
1st attempt, 2nd attempt and the last attempt before calling it a night. You can see the bead gets smaller, less crap and a better aim.

I did need to spend time reading the manual, adjusting my head gear and learning to hit the spot and not stay on it too long. The next welds should have better penetration. I did grind down the edges to a 45 angle (to create a trough between the two pieces) and polished the steel area to make sure it was clean.

Out to practice some more.

 

[MadMikeyL]

What you have is not a MIG welder. What you have is a flux core welder. They are different. They weld differently. A properly set up MIG can make nice welds, not TIG level stacking dimes, but nice enough. Flux core will never look nice. I know they are significantly more expensive to buy, but the results are going to be night and day, and it will be much easier to learn on and get used to.

 

[Fred Smailes]

There are probably a few vids on YouTube to get you going down the right road with flux core.

 

[Grog6]

I'd see if a local cc has an intro class you could take.

 

[White Lincoln]

Thanks guys. From the videos I have watched, I thought Flex core (e-hem) seams look nice. I did some more practice welding on pipes today and am getting a little better. I do have some issues with balance and technique, but that gets better with practice. I have a lot of practice pipe to use, and the tools to make it all happen: grinder, polisher and cutter. I think as I practice more, the welds are going to come out nice.

We do have MiG welding classes (Flux Core?) at our local Central New Mexico Community College (which I worked at for 10 years) and unless you are going for a degree, it is like $90. But I don't think I need to go that far, it is not hard to weld exhuast and from what I have read, Flux Core is the way to go to seal up those pesky joints.

 

[White Lincoln]

After working on some pipe again, I decided it was time to make something to HOLD the pipe in place instead of using my vise.

I welded two pieces of scrap metal at a 45 deg, then put a flat bar under the V with a long flat peice. It can be clamped down if needed. I noticed two things, I was getting a stream of tiny, tiny coins and it was penetrating too. But I still have slow and steady movement as an issue. I think I need thicker wire to make larger weld beads.

 

[XR7-4.6]

I’m actually fairly impressed you didn’t get much if any blow through I can see. I’ve been toying with getting a cheap flux core just to tack an exhaust together now that I have to redo the front half and pay someone to fully weld it without bringing them the car and having them cut and shape all the pipe.

I’d get a MIG but I just don’t have the space for it and the tanks for the minimal use I’d get out of it, let alone the cost

 

[Grog6]

I need to get new regulator and hoses for the cutting torch I have, and get the tanks refilled or replaced, and learn to use the stick welder I have. I'll buy a book and go from there. I've learned a lot that way. One of my great nephews buddies does aluminum, and he said he'd weld up my manifold if I fix an amp for him. Amps are easy. Tape decks, not so much. Took me 4 hours the other night to put on a belt,lol.

 

[White Lincoln]

I’m actually fairly impressed you didn’t get much if any blow through I can see. I’ve been toying with getting a cheap flux core just to tack an exhaust together now that I have to redo the front half and pay someone to fully weld it without bringing them the car and having them cut and shape all the pipe.

I’d get a MIG but I just don’t have the space for it and the tanks for the minimal use I’d get out of it, let alone the cost

I have to say that you are thinking on the same line as I was. Why pay someone several hundred dollars to do 8 welds on my exhaust when I can get a flux core welder for $120, some wire for another $20, cheap helmet that does the job for $40, plug it in and start learning on scrap pipe?!

Anyway, here is my 1st welds (horrible looking splatter weld). The second one is my 4th shot at welding that I did today. I was practicing on short sections because I am having trouble seeing where I am welding. But I am getting the weld much closer to being correct the more I practice. I say its not bad to be welding like that only after 4 tries. Worth it for me to learn a new skill anyway since I may not have a job after January.

 

[White Lincoln]

I need to get new regulator and hoses for the cutting torch I have, and get the tanks refilled or replaced, and learn to use the stick welder I have. I'll buy a book and go from there. I've learned a lot that way. One of my great nephews buddies does aluminum, and he said he'd weld up my manifold if I fix an amp for him. Amps are easy. Tape decks, not so much. Took me 4 hours the other night to put on a belt,lol.

Ooooo cutting torch... wish I had one! They come in very handy when working on cars, especially modifications or major changes, like removing rusty parts to weld back in clean, hole free sheet metal. I think stick welding is much the same as MiG / Flux Core, just better. And I have been there too... spend an hour trying to fix a stupid cassette player pulley belt. Enjoy learning!

 

[White Lincoln]

I’m actually fairly impressed you didn’t get much if any blow through I can see.

Tip:
DO NOT leave your coffee cup anywhere you are welding. Not only will crap float in the air and settle in your cup, but the fly away will stick to the porcelain and not come off! I carelessly took my coffee in with me before welding, sat down, put my cup a foot or so away from the welding area and next thing I know, there are black dots all over the one side of my cup. "no biggy, I will just wash them off" HA! Fat chance.

Luckily, it was a Dollar Tree coffee cup.

 

[racecougar]

On the flip side, if you learn how to weld sheetmetal with flux core, when you make the move to MIG, it'll be easy street. That was my path.

 

[White Lincoln]

On the flip side, if you learn how to weld sheetmetal with flux core, when you make the move to MIG, it'll be easy street. That was my path.

Excellent advice and comment. Thank you.

 

[dDUBb]

I did grind down the edges to a 45 angle (to create a trough between the two pieces)

Why not swage one end to make a lap joint weld ?

30 max with a nickel thick landing if we're working big boy pipe.

I think stick welding is much the same as MiG / Flux Core, just better.

 

[White Lincoln]

Hey dDub.... you went right over my head with your comment....

 

[dDUBb]

 

[dDUBb]

Hey dDub.... you went right over my head with your comment....

I build complex heating and cooling systems for commercial and industrial applications for a living.



Cal State University Science building



Palo Alto VA Medical center - Cath Lab upgrade



Stainless TIG for Clean Steam Humidifier ... when you can weld like this, I have a job for you at $135 / hr.


Just to clarify my previous comment .. Swaging = Pipe expander to make a socket fitting and lap weld versus a butt weld. We cant expand schedule 40 steel pipe like exhaust tubing.

We do not "Bevel" pipes - its more of a Chamfer, we leave the landing at 1/8" ( Nickel thickness ) for the root pass. I dont want 45 degrees, too much gap to fill .. 30 degrees is what I expect to see from my fitters.

The joke meme is that 6010 welder weld downhill .. and 7018 needs to go uphill; so the welder has to stand on his head to make the pass. If you got the joke, I could justify that one weld process is better than another but the reality is that they each have their own application.

 

[White Lincoln]

<shock and awe....>
Awesome, just awesome dDub. Thanks for the explanation.

I was humming this all day today after my 5th day of not so progressive welding skills....

[from 'Learning to Fly' (Tom Petty and the Heartbreakers song)]

Well, I started out trying to weld
Started out with no help at all
And I turned the flux dial down
And the stick lit up, the metal went down

I'm learning to weld, but I can't make a dime
Holding still is the hardest thing

Well, my golden days, may never be
And the steel might melt and my cloths may burn

[Chorus]
I'm learning to weld (Learning to weld)
But I can't make a dime (Learning to weld)
Holding still (Learning to weld)
Is the hardest thing (Learning to weld)

Well, some say perfection will beat you down
Break your flux, steal your core
So I've started out learning to weld
I guess I'll know when I can make a dime.

 

[dDUBb]

I was humming this all day today after my 5th day of not so progressive welding skills....

5 days IS progress.

I did my first welds over 25 years ago, with my friends flux core wire feed. It got the job done.

There are enough people here with welding experience to answer any questions you might have .. but the best teacher will be from the amount of time you spend under the hood.

 

[Ericv8thunderbird]

Flux core isn’t terrible, it’s tough to get used to it, you can blow through sheet metal easily. I’ve mig welded and that’s much easier.

But, I did use a flux core to do the frame rails in my Turbo Coupe, this was after I grinded and cleaned up the welds

 

[theterminator93]

I've always had an admiration for guys who can weld. Props for taking the leap to learn.

 

[White Lincoln]

Again, thanks guys for the support. I appreciate the moral backing that this can be done if you just try. My welds look like a 5 year old did them, but they are holding. I must have my settings correct because like Zep said, I don't have very much spatter, which is really nice and only blew a hole twice I think on the exhaust. I just throw a blob over it...