31
Issue
Lack of Fusion − failure of
weld metal to fuse
completely with base metal
or a proceeding weld bead
Excessive Penetration −
weld metal melting through
base metal
Lack of Penetration −
shallow fusion between
weld metal and base metal
No gas flow
Possible Reason
• Contaminated base metal
• Not enough heat input
• Improper welding technique
• Too much heat
• Poor or incorrect joint
preparation
• Not enough heat input
• Contaminated base metal
• Gas Regulator is off or
pressure too low
• Something caught in the valve
• Solenoid valve is damaged,
Suggested Remedy
• Remove materials like paint, grease, oil, and
dirt, including mill scale from base metal
• Select a higher voltage range and /or adjust
the wire speed to suit
Keep the arc at the leading edge of the weld
pool. Gun angle to work should be between 5 &
15° Direct the arc at the weld joint
Adjust work angle or widen groove to access
bottom during welding, Momentarily hold arc on
side walls if using weaving technique
• Select a lower voltage range
• Material too thick. Joint preparation and
design needs to allow access to bottom of
groove while maintaining proper welding wire
extension and arc characteristics Keep the arc
at the leading edge of the weld pool and
maintain the gun angle at 5 & 15° keeping the
stick out between 5-10mm
• Select a higher voltage range and
• Remove materials like paint, grease, oil, and
dirt, including mill scale from base metal
Check Regulator
• Remove
• Contact BOSSWELD hotline
TROUBLE SHOOTING - CONTINUED
OPERATIONAL ENVIRONMENT
• Height above sea level ≤1000m
• Operation temperature range -10~+40°C
• Air relative humidity is below 90%( 20°C)
• Preferably site the machine above floor level, ensure the maximum angle does not exceed 15 degrees.
• Protect the machine against heavy rain and against direct sunshine.
• The content of dust, acid, corrosive gas in the surrounding air or substance must not exceed normal
standard.
• Take care that there is sufficient ventilation during welding. There must be at least 30cm free distance
between the machine and wall.
