Gasless Wire (Innershield) FAQs
Straight answers on choosing, setting up and troubleshooting self-shielded gasless flux-cored wire.
Can I use gasless wire outdoors in the wind?
Yes, this is one of its main strengths. Because the shielding gas is made inside the weld pool by the flux, a breeze cannot blow it away the way it can with gas-shielded MIG. That makes it popular for site repairs, farm and fencing work, and fabrication outdoors.
Very strong wind can still disturb the arc and spread slag and spatter, so shelter the weld where practical. Keep the arc length steady and clean the joint well, because outdoor jobs are often dirty.
What does a classification such as E71T-11 tell me?
It is a public classification that describes the wire. In general terms the E means an electrode, the 7 relates to its tensile strength class, the 1 means it can be used in all positions, the T means it is a tubular (flux-cored) wire, and the last number describes the type of flux and the shielding and polarity it is designed for. An -11 wire is typically self-shielded and run on electrode negative.
Check the standard or the maker's data sheet for the full detail, and use the classification to compare wires from different makers rather than relying on the product name.
How much stickout should I use with gasless wire?
Stickout is the length of wire between the contact tip and the work. Gasless wire normally runs with a longer stickout than solid MIG wire; around twice as long is a common rule of thumb. A longer stickout preheats the wire and keeps the flux working properly.
Too long a stickout causes porosity, an unstable arc and burnback to the tip, while too short gives excessive spatter and overheats the tip. Follow the wire's data sheet for the right range and adjust in small steps.
Which drive rolls and tension should I use for gasless wire?
Flux-cored wire is a soft tube, so it can be squashed by too much pressure. Knurled (grooved) drive rolls grip it well without crushing it, whereas the smooth V-groove rolls used for solid steel wire may slip.
Set the drive roll tension just high enough to feed the wire without slipping, as set out in the machine manual. A crushed or flattened wire shows as erratic feeding and a rough arc. Match the roll groove to the wire diameter.