Troubleshooting
Why is my flux-core welding excessive spatter?
Quick answer
Excessive spatter in flux-core welding usually means too high current for the wire, too long stick-out, or wrong polarity on gasless wire. For this process, verify DCEN and stick-out before touching anything else.
The specific fix
Verify DCEN and stick-out. The general rule: drop the voltage a step, shorten stick-out, verify polarity on the wire packet.
Process checklist
- Wrong polarity — most gasless wire wants DCEN (electrode negative); check the packet
- Dragging the gun like stick — gasless likes a slight drag angle, unlike gas MIG
- Leaving slag-capped wormholes by welding too slow or too hot