TEC.LA Ergus WIG 160 CDI, User Manual

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NB: Descending welding needs a quick movement, while ascending welding needs a slow movement which heats
the material to be welded.

Overhead: the electrode works upwards, while the parts to weld are in a horizontal position.
FOR OPTIMAL WELDING ON MATERIALS OF CONSISTENT THICKNESS, THE EDGES TO BE JOINED
SHOULD BE PREPARED FOR WELDING BEFORE PROCEEDING.
2. Electrode welding defects–troubleshooting
DEFECT POSSIBLE CAUSES REMEDIES
1. Air bubbles in the bead
(porosity).
A. Wet electrodes.
B. Welding current to high.
C. Greasy or painted Surfaces
A. Dry electrodes before use.
B. Reduce welding current.
C. Clean joints before welding them.
2. Visible cracks in the bead
immediately after
solidification.
A. Joints too rigid.
B. Welding throat too thin.
C. Cooling too quick.
A. Eliminate tension problems due to the
shape of joints.
B. Reduce welding speed to allow for a
thicker deposit.
C. Pre-heat the piece and cool it more
slowly.
3. Fissure due to slight filling of
the split.
A. Welding current too low.
B. Electrode too big for the joint.
C. Insufficient split.
D. Incorrect welding sequence. A. Increase welding current.
B. Use electrodes of a smaller diameter.
C. Enlarge split.
D. Place the pieces in a correct sequence.
4. Portions of the welded piece
not melted with the sheet
metal or with the joint.
A. Electrodes too thin for the
piece to be welded.
B. Welding current too low.
C. Electrode used with incorrect
slope.
D. Weldingf speed too fast.
E. Slag or dirt on the surface of
the piece.
A. Use electrodes of a larger diameter and
pre-heat the piece.
B. Increase welding current.
C. Correct the welding angle towards the
base plate.
D. Reduce the welding speed.
E. Clean the surface before welding.
5. Non metallic material
trapped in the weld bead
(slag included).
A. Particles trapped in the lower
layers of the preceding
passages.
B. Joint prepared too tight.
C. An irregular deposit helps the
slag to stay trapped.
D. Slight penetration with slag
trapped under the welding
bath.
E. Rust or chips prevent total
melting.
F. Wrong electrode for the
welding position.
A. In situations of slight base welding, clean
slag and pass on the base again with an
electrode of a smaller diameter.
B. Guarantee enough space for slag
cleaning.
C. If necessary, grind the slight or the
irregular part.
D. Remove all slag from corners. Use
smaller electrodes with higher current for
suitable penetration.
E. Clean the joint before welding.
F. Use electrodes suited to the welding
position, otherwise it will be difficult to
remove the slag.