33
1: No arc
0/33)",%2%!3/.
35''%34%$2%-%$9
Incomplete welding circuit
#ONlRMTHATTHEGROUNDCLAMPISCONNECTED#HECKALLCABLECONNECTIONS
Wrong mode selected
#HECKTHE34)#+SELECTORSWITCHISSELECTED
No power supply
#HECKTHATTHEMACHINEISSWITCHEDONANDHASAPOWERSUPPLY
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
0/33)",%2%!3/.
35''%34%$2%-%$9
Arc length too long
3HORTENTHEARCLENGTH
Work piece dirty, contaminated or moisture
2EMOVEMOISTUREANDMATERIALSLIKEPAINTGREASEOILANDDIRTINCLUDINGMILLSCALEFROMBASEMETAL
Damp electrodes
5SEONLYDRYELECTRODES
3: Excessive Spatter
0/33)",%2%!3/.
35''%34%$2%-%$9
Amperage too high
$ECREASETHEAMPERAGEORCHOOSEALARGERELECTRODE
Arc length too long
3HORTENTHEARCLENGTH
4: Weld sits on top, lack of fusion
0/33)",%2%!3/.
35''%34%$2%-%$9
Insufficient heat input
)NCREASETHEAMPERAGE
Work piece dirty, contaminated or moisture
2EMOVEMOISTUREANDMATERIALSLIKEPAINTGREASEOILANDDIRTINCLUDINGMILLSCALEFROMBASEMETAL
Poor welding technique
5SETHECORRECTWELDINGTECHNIQUEORSEEKASSISTANCEFORTHECORRECTTECHNIQUE
5: Lack of penetration
0/33)",%2%!3/.
35''%34%$2%-%$9
Insufficient heat input
)NCREASETHEAMPERAGE
Poor welding technique
5SETHECORRECTWELDINGTECHNIQUEORSEEKASSISTANCEFORTHECORRECTTECHNIQUE
Poor joint preparation
#HECKTHEJOINTDESIGNANDlTUPMAKESURETHEMATERIALISNOTTOOTHICK
3EEKASSISTANCEFORTHECORRECTJOINTDESIGNANDlTUP
6: Excessive penetration –burn through
0/33)",%2%!3/.
35''%34%$2%-%$9
Excessive heat input
2EDUCETHEAMPERAGE
Incorrect travel speed
4RYINCREASINGTHEWELDTRAVELSPEED
7: Uneven weld appearance
0/33)",%2%!3/.
35''%34%$2%-%$9
Unsteady hand, wavering hand
5SETWOHANDSWHEREPOSSIBLETOSTEADYUPPRACTICEYOURTECHNIQUE
8: Distortion − movement of base metal during welding
0/33)",%2%!3/.
35''%34%$2%-%$9
Excessive heat input
2EDUCETHEAMPERAGE
Poor welding technique
5SETHECORRECTWELDINGTECHNIQUEORSEEKASSISTANCEFORTHECORRECTTECHNIQUE
Poor joint preparation and or joint design
#HECKTHEJOINTDESIGNANDlTUPMAKESURETHEMATERIALISNOTTOOTHICK
3EEKASSISTANCEFORTHECORRECTJOINTDESIGNANDlTUP
9: Electrode welds with different or unusual arc characteristic
0/33)",%2%!3/.
35''%34%$2%-%$9
Incorrect polarity
#HANGETHEPOLARITYCHECKTHEELECTRODEMANUFACTURERFORCORRECTPOLARITY
4HEFOLLOWINGCHARTADDRESSESSOMEOFTHECOMMONPROBLEMSOF3-!73TICK WELDING)NALLCASESOFEQUIPMENTMALFUNCTION
THEMANUFACTURERSRECOMMENDATIONSSHOULDBESTRICTLYADHEREDTOANDFOLLOWED
SMAW (STICK) WELDING TROUBLESHOOTING
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