Pat you will lose ability to penetrate larger stuff , flux core is the best for small amp welders . Flux core burns hotter than the mig wire .
Also run 023 wire that welder will have a hard time burning 035 wire with gas . And you might want to try a tri mix gas , argon helium and co2 . This gas burns hotter than 75-25 and really helps a small welder . I have a Hobart 140 and run the tri mix though it . And one more thing run that little Lincoln wide open heat wise and then work down if your burning shit up . If you have anymore questions just ask .
David, good to see you post here. I get at least 1/8" with .024 and 25/75. True, there is better penetration with flux wire, but I have never needed that extra penetration, (advertised .25" but I doubt it) with any of my mini bike projects. Not to mention the extra splatter.
I only have about six years of hobby experience with welding, so I had to look up the Tri Gas.
With regard to tri-gas, it does not make a hotter arc. What it does is allows for "spray transfer" with less splatter, which is a technique used for out of place welding, or SS. These small welders don't have enough amperage for that anyway.
The same place I got the above info from also says the 25/75 is good for .035 and .045 wire! Well hells bells, all I use is .024.
I need to replace my inert gas now anyway, and have no problem experimenting. Do you have practical, empirical experience with using Tri Mix on a 140 with .025 and mild steel?
I'd like to get better looking welds, and get more control over my penetration. I do agree with you that keeping the current turned up high, then adjusting feed and distance with the wire is the way to go with these! :thumbsup: