I saw something yesterday i haven't seen or maybe i have, but never really found out what it was. We're running an ESAB E81T1-Ni1mH4 flux cored .045 wire on 3/8" armor plate. Yesterday i went to a subcontractors shop to see what they got going on and i had them weld a few coupons for me and this is what i saw. They were getting these dimples all in a row about an 1/8" in from the top toe and bottom toe of the weld. It looked like porosity, but there were no holes. In a few of the dimples there looked to be a some small BB's with flat tops just sittin in these tiny craters. It looked kinda like someone took a writing pen and just started peckin all these lil dents along one side of the weld or sometimes both sides, but never down the center.
Now the trouble shooting that has allready been done to fix the prob. Played with gas flow= nothing, Checked o-rings and for leakes=None, Tried to brand new rolls of wire=Nothing, made sure of no Contaminants=Nothing, went from 26v with proper amount of wire to 29v with proper wire setting=helped some, but still showed signs of the dents.
Here where i work we have had no problems with this wire running anywhere from 22v to 29v.
I would just like to know what these lil dents with BB's in them are and if you what might know how to fix the prob it would be greatly appreciated!!
Thanks, Kix