I'm got some new sheet metal to weld in and I have a miller 135 wire feed welder have been using .030 flux core wire I've been working on a test panel and have had to lower the amps to the lowest setting to keep it from burning through. is there a better way to do this ? I understand to only do spot weld and come back in fill in so not to warp the panel. any info on this skill would be helpful. thanks
If you are trying to weld automotive sheetmetal together with one continuous bead then that is your first mistake. Welds are done in only about half inch increments then come back and fill in if necessary. d
I would suggest useing little tacks (hold the arc there for just a little bit in a circular motion like a small circle or "dot" ) and make one tack then on the opposite side so the other end does not lift upwards. When you have it all tacked make the welds longer but like you said fill in areas each a little at a time to spread the heat and avoid warpage. I do no know what you area the plate is going but you do not have to have a solid weld all the way around many things. Alternate stitch welds are very strong save time and material if solid full welds are not required.
I'm doing the tail light housing car had been rear ended at some point and I got some that are in perfect shape. thanks for the help any body else have there 2 cents worth? thanks
In that case you are going to need full welds. Good thing is there are grinders if you no like you grind you try again.
Never tried it personally but I've been told flux core wire won't give you good results with thin sheetmetal. Too much heat. I have had good results on thin sheetmetal with .023 MIG wire.
I Agree with what vince says I would use normal mig wire. I see flux core at work welding big cracks in big vessels so flux is for thick steel.
