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FAQ - Knowledge and Support Zika Industrial Welding Supplies


Is there a way to control the wire speed in the MIG-200 welding machine?

The wire speed and welding current are controlled together with the Current dial. A rise in current carries rise in wire speed, and vice versa. It is not possible to control the welding current separately from the wire speed in this welding machine.

The pressure regulator does not stop releasing gas, and the bottle depletes rather quickly. How to solve this problem?

The problem is most likely with the CO2 regulator itself. It is to be replace/repaired. This problem is to be distinguished from the intentional “Post Flow” – the release of gas a few seconds after releasing the trigger, for the purpose of protecting the end of the weld.

What to do if the welding wire gets stuck in my MIG welder?

Make sure the wire is clean with no rust spots and not entangled on the drum. The feeder rolls fit the diameter and material of the wire, and placed inside the notch of the feeder rolls. The feeder bolt is sufficiently tightened, the electrode lead is laid out straight with no sharp twists, the contact tip fits the wire diameter, is clean and not worn.

Why is the wire speed in my MIG welding machine slow and unchanging, even when I change the wire speed dial?

In advanced welding machines the wire speed stays slow as long as the welding circuit is open. Once you start welding the wire speed will go up according to the setting of the speed dial.

What can be done if the pressure regulator freezes?

Argon gas regulator can accumulate moisture and even ice from outside, but the Argon gas inside the system is not likely to freeze. The freezing temperature of Argon Gas is -190Deg C. CO2, on the other hand, has a relatively high freezing temperature at -78.5Deg C. and this is the reason CO2 regulators with heaters are recommended for use when welding for prolonged periods of time. If the gas freezes in the regulator, a blockage of ice is formed inside the gas tube and insufficient quantity of gas reaches the weld to protect it. It is important to verify what is the input voltage of the regulator: a 36V regulator connects to the socket in the welding machine itself. A 220V regulator is to be plugged to a regular 220V outlet. Note: if a 220V regulator is mistakenly connected to the 36V outlet in the welding machine, no damage is done, but if a 36V regulator is connected to a 220V outlet, most probably it will be burnt.

Why does my MIG Welding machine have only dials for Voltage and wire speed, and no Amperage dial?

MIG welding machines are Constant Voltage (CV) machines (unlike TIG and Stick welding machines that are Constant Current CC). The amperage changes automatically such that the distance between the tip of the welding wire to the parent material (also known as arc length) is kept constant: when the arc length shortens, and in order to prevent sticking of the welding wire to the parent material the amperage rises, the wire gets consumed faster – resulting in increased arc length. When the arc length gets longer, and in order to prevent losing the welding arc the amperage drops, the wire gets consumed slower – resulting in decreased arc length. Arc length can change due to welder movement or due to change in wire feed speed.

What length extension cord can be used for a welding machine, and what is the effect?

Voltage loss through the extension cord is current times it’s electrical resistance. The extension cord resistance depends on several factors: material (usually copper), cross section of the cable, supply electric grid voltage, number of phases, number of conductors for each phase and the length of the extension cord. Generally speaking, as long as the extension cord cross section is of the same cross section of the supply cable of the machine and the length is under 50m, the voltage drop is within the work range of the machine. For longer extension cords a full calculation is needed to find a proper cross section for the extension cord.

what are the rods recommended to use for Soldering?

The rods most commonly used for soldering have a high content of tin. 50/50 is the preferred rod (50% tin and 50% lead). Tin-zinc is used for soldering Aluminum. Lead-Silver is used for welding steel and cast iron, where the Silver decreases the melting point of lead and increases the wetting performance.

Is it possible to cut metal plates with an electrode?

Yes! Electrode Z-2002 of the Zika 2000 series is used for cutting and piercing. Usable in all positions. Effective for all types of metals: mild steel, stainless steel, cast iron, nickel base alloys, aluminum alloys, armor steels, hard metals and difficult to machine steels.

What solutions are there for extracting broken bolts?

The Z-2911 electrodes creates an especially strong welding material resistant to

twisting stress.


What solutions are there for releasing seized bolts?

Zika has a new solution for releasing seized bolts with the Z-101 spray. An exclusive formula using the best ingrediencies.

What does the abbreviation AWS stand for?

AWS is the abbreviation for the American Welding Society. The American Welding Society (AWS) was founded in 1919, as a nonprofit organization with a global mission to advance the science, technology and application of welding and allied joining and cutting processes, including brazing, soldering and thermal spraying.

How to perform filling and hard facing by welding?

For hard facing it is recommended to weld the first pass with minimal current, thus minimizing the mixing of the parent material (that is soft) with the hard-facing material. The second pass can be welded using the normal current. Hard-facing Manganese steel, an intermediate layer with Z-2411 is required. When there is need to fill up an area or build up a part before hard-facing it, the filling is to be done with Z-2900 or a filling electrode Z-2411 and use a hard-facing electrode only for the top passes. A hard-facing electrode is to be applied at two layers maximum, unless written otherwise. A hard-facing electrode produces a hard weld, but not necessarily a very strong one, at times cracks may appear on the weld surface. This is acceptable, and not to raise concern.

On an X-ray photo of welded pipe connection, small and scattered porosity was identified, what to do?

If the pores are scattered and of 0.5mm diameter or less, nothing should be done. The standards allow for it.

Is there need to dry all types of electrodes?

No. Only low-hydrogen electrodes are to be dried. Drying instructions appear on the electrode box and on the Zika catalog.

What is Slag and when to remove it?

Slag is a layer molten flux and impurities floating on top the melted weld pool. Their role is to cover the formed weld and protect it. Slowing the cool down rate and shielding for the surrounding air. After the welding process is complete and sufficiently cooled down, the flux is to be removed. It is important that removing the slag is as easy as possible, or that the slag lifts and drops by itself. The slag drops by itself due to different thermal expansion than the workpiece during cooldown.

What is the difference between flux-cored wire T1 and flux-cored wire T5?

Flux-cored wire T1 is rutile and T5 is basic. The mechanical properties of basic T5 flux-cored wire are better than the rutile T1 wire.

What is the Z-11 electrode used for?

Z-11 is a rutile electrode suitable for welding of structures, pipes, vessels, machine parts. An electrode for all welding positions.

What electrode is to be used for galvanized steel?

The most suitable electrode is Z-6. A galvanized pipe is to be welded with Z-610.

What is the length of welding circuit (Electrode Lead and Workpiece Lead) can be used for a welding machine, and what is the effect?

Voltage loss through the extension cord is current times it’s electrical resistance. The extension cord resistance depends on several factors: material (usually copper), cross section of the cable, grid voltage, number of phases, number of conductors for each phase and the length of the extension cord. Since the current in the welding circuit are ten times the input current, voltage loss is ten times as well. As long as the extended welding circuit is under 5m more than the original welding circuit length, the voltage drop is within the work range of the machine. For longer extension a full calculation is needed.

What is ARC FORCE and when to use it?

The welder controls the arc length by moving the electrode tip relative to the parent material. Arc voltage drops as the arc length shortens. (voltage controls the width and cap height of the weld bead) Welding current changes as the voltage changes. The relations between the voltage and amperage is dependent on the welding machine and is called the Slope. (current controls penetration of the weld bead).

Advanced welding machines of the inverter type have a Constant Current slope (CC). such machines produce nice looking welds, with constant penetration, even if the welders arm is not stable and the arc length changes. ARC FORCE changes the CC Slope and increases the current at low voltages (short arc). The two main benefits of ARC FORCE are: 1. Allows the welder to rise the current and increase the penetration by changing the arc length. 2. Helps avoid electrode sticking to the parent material when striking an arc. Use of ARC FORCE is to be avoided when working with thin plates – a short arc will rise the amperage and therefore the penetration and a hole can be formed.

what is HOT START and when to use it?

A temporary increase (half a second) of the welding current when starting to weld, helps create an arc quickly and reliably, without the electrode sticking or damage to the work piece.

What are the main considerations when selecting between W-200 welding machine and the MINI-160 welding machine?

The W-200 is more suitable for repair, spot jobs and amateurs. The MINI-160 is physically larger, with more durable components and better ventilation making it more suitable for more professional jobs for longer stretches of time.

Is it possible to connect a TIG electrode holder to a MIG welding machine? What about connecting a TIG electrode holder to a MMA (stick electrode) welding machine?

MIG welding has Constant Voltage slope (CV). TIG and MMA have Constant Current slope (CC). The slope determines the behavior of the welding arc, and it will be hard to strike and maintain TIG arc using a MIG welding machine. However, connecting a TIG electrode holder to an MMA welding machine is possible, because they have the same type of slope.

What is the Best practices, to weld steel pipe welding ?

Welding is the most economical and efficient way to join permanently two or more pieces of metal and make them act as a single piece.

This is possible by using the welding equipments: machines able to generate and transform the current in order to heat and therefore smelt the metal.
There are different ways and solutions to obtain the smelting of the metal, that we can mainly resume in three procedures: mma, tig, mig.

What is the equipment needed for Soldering?

There are two methods of soldering:

Brazing – designed for materials whose melting point is 425ºC or more.

Soldering – designed for materials whose melting point is less than 425ºC.

Soldering does not give the connection very high mechanical properties. Good preparation is required to increase the strength of the connection (by folding the edges, tack welding, riveting, etc.).

Soldering by itself mainly provides sealing for liquids and gases, or to provide good electrical conductivity. There are different methods to melt the soldering material: dipping, oven, spray gun, electrical resistance, induction, Oxy-Fuel, ultrasound, infrared. No matter what type of heat source is used, the main importance is controlling the melting point of the soldering filler metal.

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