Can You Use MIG Wire in A Flux Core Welder?

Flux core and MIG welder are a bit different in characteristics. The MIG wire is solid, and the flux core wire is like a hollow tube. Therefore, can you use MIG wire in a flux core welder? What will happen then?

You can use the MIG wire in a flux core welder. But the gas needs to be available in the system. For that, you need to make some moderations on your flux core welder to create a way for shielding gas. Check out the MIG wire pull-out speed and adjust the pressure. And don’t forget to adjust the polarity before starting welding.

If you can make the moderations with proper guidelines, you can use MIG wires in a flux core welder.

MIG Welding Wire Vs. Flux Core Welding Wire

A MIG welder mainly uses a solid wire to weld on any metallic surface. On the other hand, a flux core welder uses a hollow tube wire to weld.

You would need a tank of shielding gas as feed in the torch that helps move the wire during welding. The flux core welder also needs shielding gas, but it will flow inside the hollow space of the wire. That also produces a productive gas during welding.

MIG Wires in the Flux Core Welder

Well, you can use MIG wires in the flux core welder despite their structural dissimilarities. But at first, you should know the flux core welding wire types: self-shielded and gas-shielded.

The gas-shielded flux welders need external shielding gas to help the wire move and increase the welding rate. However, the self-shielded flux core welders don’t need any shielding gases in assisting in the pathway of the wires. They mainly use gasless flux core welding wires.

Therefore, if you want to use MIG wires in such flux cores, you need conversion kits that will help create separate gas lines at the end of the gun or torch.

And also, be aware of the polarity. Otherwise, there will be more splatters than necessary, and the attachment won’t have enough strength to hold on to the surface.

When Can You Use MIG Wire in A Flux Welder?

It’s not usual to use MIG wires in a flux welder. Even though you are in the middle of welding, you can’t just remove the flux wire and attach a MIG wire to weld.

You can take such measures when you have no alternate options like running out of flux wires, unused flux welder, a surface that needs to weld with MIG wires, etc. But before that, learn MIG welding wire types to avoid unsuccessful outcomes.

Even when you ought to buy a welding machine rather than using your old flux core welder, you can just modify your old one with some conversion kits and make it suitable to use.

How To Use MIG Wire in A Flux Welder?

Suppose you have decided to use MIG wires in your flux core welder. But how should you proceed?  Well, here’s what to do:

Step 1: Remove Unnecessary Parts

Due to structural differences, you don’t need all the parts of a flux welder while converting it into a MIG welder.

If possible, get an electronic solenoid valve to adjust gas flow while welding.

Step 2: Assemble the Circuit

How do you actuate the valve at the same time when the welder feeds wire? Well, you need to develop the circuit.

Therefore, use a cooling fan connecting with the relay and solenoid valve. The control loop helps move the wire forward and pass the gas flow accordingly.

Step 3: Attach the Way of Shielding Gas

Now it’s time to make a pathway for shielding gas.

For that, rob the gas shield valve in 90-degree and attach the gas nozzle with an elbow (45-degree). The hose should start from the solenoid to the end of the whip onto the elbow.

Step 4: Test the Welding

Well, all the settings are done, and now you have to test the welding. The result may satisfy you, but melted metal’s holding capacity is close to zero.

But why? Just because of the polarity. You won’t see any penetration over the metal surface after the welding.

Step 5: Check Out the Polarity

So, when switching from flux welding to MIG welding with shielded wire, you also need to swap the polarity. Make the electrode positive and the ground negative as you are using DC.

Step 6: Adjust the Power and Final Test

After that, test the welding again and adjust the power according to your demand. You can use welding on the actual surface when the calibration is complete.

Is It Worth Using MIG Wire in A Flux Welder?

Well, you might be thinking that all these efforts, time, and money on the MIG wires on a flux welder is worth it or not. We would say it depends on your conversion kits.

If you need to buy all the conversion kits, it may not be worth it. That’s because you can get a MIG welder for the same price as this flux core welder (even though we are keeping the extra costs aside).

On top of that, the dual shield flux core wire can handle better penetration in the thick walls.

Pro-Tips Regarding Using MIG Wire in A Flux Welder

While using a MIG wire inside your flux welder, you would need some tips to follow to get better results.

You need to adjust the shielding gas pressure and the travel speed of the wire. Otherwise, the wire will have an excess decay rate. And obviously, don’t forget to swap the polarity, or else your whole welding work will go in vain.

Bottom Line

Switching from flux core wire to MIG wire is not a bad idea. But you have to keep in mind some crucial facts about conversion regarding shielding gas, polarity, and travel speed.

Hopefully, your confusion about-can you use a MIG wire in a flux core welder or not has been clarified. Be careful while working on welding jobs!

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