Fanuc welder
So 2 days into trouble shooting as well as re-mastering as well as calibrating and the robot is just randomly throwing large multiple foot long clusters of porosity happening. Its flat surface 90/10 gas and setting of 28V, 475WFS, travel speed of 30, weave of freq of 5, amp of 4.8, and .15 on both left and right side hang.
It doesnt seem to have any sign of where itll happen but its consistently pulling out large clusters of porosity. Ive grinded it down at least 4 times a few times taking even the root out and redoing it. Im the only robot guy the place has so only troubleshooting is what I think of or the 5 hours Ive spent on the phone with fanuc over other issues.
It all started with the robot throwing the binzl alarm or what not for dead batteries. Re-mastered and re-calibrated on the phone with Fanuc because the first try didnt seem to work. Re-uploaded AoA back up as well as directed by Fanuc. Robot finally got up and running and try to run a 9ft stringer on a product and like 4 ft of porosity. Ran another bead over half of it and somehow the 2nd bead had little to no porosity. The only porosity was from the first bead where it was overlapping. Gas input on the back of the robot is free spinning but the hose still has a seal and theres no leak or suck in of air that can be found.(soapy water on the hose was used and nada) Gas is a 90-95% full tank and the robot doesnt have any air hooked up to it.
The settings I gave isnt the exact settings for each bead ran because I was trying to adjust to see if that would fix it. So +/- 10% of those numbers is the range roughly of what I used across probably 25-30 beads. If I weld 6~inch or less it looks fine. No porosity or any defects. If I weld a long bead the 1st foot I think has always been good and than at some point you might as well be shooting water into the nozzle while welding.
Im at a loss as to what the cause is, the metal is all from the same batch from our vender with the same melt/heat number so from my understanding all the metal should be the same. The wire, gas, base metal are the 3 constants; using a hand welder, or either of the robots on this metal always pulls porosity and Im not the only one to try rooting it. Everytime porosity happens its grinded out a 1/16 an inch past the last porosity to verify there isnt some hidden.
The base metal being bad is a possibility but we've used this vender for years and never once had an issue anything like this so presumably its not that. Ive heard of bad gas but never had it before; Ive also been told its extremely rare and someone I work with has only encountered it once in 20 years. I cant imagine the wire is bad though given it was a new spool still wrapped in plastic and boxed from the factory.
So any ideas of what Im missing or forgetting? Or if the gas/wire is realistically the issue how do I test that? We have different spools of the same wire and 3 of them have been opened and used across the 2 robots and hand welder.