The most common of these errors in the setup include: Using improper setting for the material you are welding or the type of wire you are using to produce your welds can be another cause of pulsing and stuttering with your Mig welder. How To Find The Correct MIG Welder Settings > Check out the video below These fluctuations can produce a stuttering or pulsing effect at the torch as the heat goes up and down at the weld. A bad ground caused by a dirty or worn clamp, or a broken or worn ground lead can cause fluctuations in the current from the welder. Bad Ground – Maintaining a good circuit is necessary to produce clean even welds.A damaged tip can easily become a binding point for the wire and cause stuttering or pulsing at the weld. High heat, splatter, and operator abuse (dropping the torch, so the tip bangs on the concrete or work) can take its toll on the tip. Failure to change tips – The tip of your torch takes a beating.These wear points can become bad enough to cause the wire to stop feeding and created a tangled mess in the wire drive assembly. ![]() The welding wire rubs on these points, wearing groves in the assembly that can become pinch points causing the wire to feed inconsistently. The spring liner in the assembly will eventually wear at the points that bends occur. Worn spring liner – The whole cable and hose assembly can be a culprit in pulsing or stuttering in your Mig welder.This jumping of the wire can cause the stuttering or pulsing at the torch. This deformation in the wire can cause feed problems at the tip, causing the wire to jump. Too much tension can also deform the welding wire. Drive roller tension to high – To much drive roller tension can add wear and tear on your welding machine.The result is inconsistent feed on the wire, which results in stuttering or pulsing at the torch. Fouled drive rollers make it harder for the drive rollers to grip the wire. The drive rollers and the drive roll groove on your machine can become packed with this lubricant. ![]()
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