help with MIG sputtering

I have a new-to-me Lincoln 250. At higher voltage/wire feed setting for thicker metals I can get a good, consistent bead. At lower settings for thinner material, there is a lot of sputtering, sometimes a pop and loss of arc...occasionally with the wire "sticking" to the tip, then jumping out.

I am using the recommended voltage/feed settings as indicated on the chart posted inside the unit. (I've also experimented with tweaking those settings and practicing.)

My gas (75argon/25CO2) is new, the regulator/hose system has been checked, and the gun is I think that the shield is ok.

MY guess is it could be the pressure screw on the wire feed...but I don't know if I should increase or decrease pressure? (I've tried a little of both...but I've not gotten a result that is reliable enough to tell me this is the solution.)



look at the drive rollers with a magnifying glass.

if they look worn, that could be the issue.

first, see how much thumb and finger pressure it takes to stop the wire feed.

pinch the wire and pull the trigger. it should take a good bit of squeezing to stop the wire feed.

also, you said the gun is new, but what about the liner?

if you are not sure about the liner, they are pretty cheap so replacing it is an option too.

i suspect the drive rollers and slipping.

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May 29, 2012
poor ground NEW
by: Anonymous

poor ground

Mar 21, 2012
Miller 250 sputtering NEW
by: Anonymous

The piece that the wire first goes through after the roll was clogged up with dirt and junk. It helped to clean that out but my 250 does the same thing when first starting the bead...after the bead is started it smooths out. I am thinking it just might be the nature of the beast.

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