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7
TROUBLESHOOTING
PROBLEM
CAUSE
CORRECTION
Contamination
in weld bead
Contaminated Electrode Rod
Make sure that Electrodes are clean and dry before use.
Contaminated Base Metal
Clean base metal of any oil, debris, coatings, or moisture. If base metal is
cold rolled steel make sure to remove any mill scale.
Poor Weld
Appearance
Incorrect positioning
The angle of the electrode should be at 45° and drug away from the weld
arc. Failing to do so may cause poor weld appearance.
Weld Bead is
Cracking
Too much heat in material
Reduce heat & allow more time between passes.
Base Metal is absorbing too much heat
Preheat base metal (consult welding codes for requirements)
Incorrect Filler Wire
Use correct fi ller wire type & diameter for the joint being welded.
Material is
Warping
Insuffi cient Clamping
Clamp work piece tightly & weld while clamps are in place.
Insuffi cient Tack Welds
Add more tack welds until rigidity and stiffness is developed.
Too Much Heat in Material
To reduce heat it is best to spread the welding out around the area. This can
be done by using stitch welding techniques, alternating sides, and/or taking
your time and allowing the pieces to cool between passes.
Porosity in
weld bead
Contaminated Electrode Rod
Make sure that Electrodes are clean and dry before use.
Contaminated base metal
Clean base metal making sure to remove any oil, debris, coatings, or moisture.
Diffi culty
Starting Arc
Incomplete Circuit
Check Ground connection. Make sure that the ground is on a freshly cleaned
surface and close to the welding area. It is suggested to weld toward the
ground connection
Amperage Too Low
Based on the material welding & size/material of the electrode, pick an
appropriate amperage to perform the desired weld.
Contaminated Base Metal
Clean base metal of any oil, debris, coatings, or moisture. If base metal is
cold rolled steel make sure to remove any mill scale.
Arc Wander
Electrode too far from welding surface
Move electrode so that it is contacting the weld puddle and feed rod into the
puddle as needed.
Diffi culty
Holding Arc
Amperage Too Low
Based on the material welding and size/material of the electrode, pick an
appropriate amperage to perform the desired weld.
Electrode too far from welding surface
Move electrode so that it is contacting the weld puddle and feed rod into the
puddle as needed.
Incomplete Circuit
Check Ground connection. Make sure that the ground is on a freshly cleaned
surface and close to the welding area. It is suggested to weld toward the
ground connection.
Contaminated Electrode Rod
Make sure that Electrodes are clean and dry before use.
Contaminated Base Metal
Clean base metal of any oil, debris, coatings, or moisture.
