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4-2. Excessive Spatter
Excessive Spatter
−
scattering of
molten metal particles that cool to
solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for
electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage
too high.
Reduce arc length or voltage.
4-3. Incomplete Fusion
Incomplete Fusion
−
failure of weld
metal to fuse completely with base
metal or a preceeding weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding.
4-4. Lack Of Penetration
Lack Of Penetration
−
shallow
fusion between weld metal and
base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Reduce travel speed.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
