Frequent Flux-Core Issues

Written By Luke Alderfer

🔥Flux-Core Troubleshooting Guide

📋 Problem: Excessive Spatter

  • Is the voltage too high?
  • Stick out too far?
  • Is travel speed inconsistent?
  • Is polarity correct?
🔧 Fix: Lower voltage slightly, shorten arc length, maintain steady travel speed, and make sure leads are hooked up right (DCEN - ground on positive and electrode negative).

📋 Problem: Burn-Through

  • Is material too thin for your heat settings?
  • Are you lingering too long in one spot?
  • Is travel speed too slow?
🔧 Fix: Adjust settings for material thickness, move steadily, avoid stopping in one spot.

📋 Problem: Inconsistent Bead

  • Are you maintaining a consistent push angle?
  • Is your wire feed speed steady?
  • Are your travel speed and distance uniform?
🔧 Fix: Keep a consistent push angle, steady wire feed, and uniform travel speed.

📋 Problem: Slag Inclusion

  • Are you not cleaning between passes?
  • Is travel speed too fast, leaving slag behind?
🔧 Fix: Chip slag between passes and slow down travel speed to allow slag to float off properly.
Luke Alderfer
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