WELD EXAMPLES & TROUBLESHOOTING
WELDING TIPS
• Smooth bead
• Minimal spatter
• Good fusion
• Stringy and lack of fusion
• Lack of fusion
• Excessive spatter
GOOD WELD
WELD SPEED TOO FAST
CURRENT TOO LOW
STICK OUT TOO LONG
• Melt through or burn through
• Too wide
• Bead too flat
•
Visible melt through
CURRENT/WFS TOO HIGH
WELD SPEED TOO SLOW
• Stickout 3/8” +/- 1/8”
• Short stickout = more
current and more
penetration
• Affects the arc shape
• Less voltage = tighter
arc and potentially
more spatter
OPTIMAL STICKOUT
THIN MATERIAL
THICK MATERIAL
Less voltage
More voltage
Lower wire feed speed
Higher wire feed speed
Faster travel speed
Slower travel speed
VOLTAGE
• Higher wire feed speed
equals more amperage
• Can also affect arc
shape and penetration
WIRE FEED SPEED
(WFS)
• Affects bead width
and height
• Can also affect
penetration
TRAVEL SPEED
3/8”
WARNING:
To prevent fire and serious injury: Keep torch and wire clear of grounded objects while
welder is plugged in.
Be sure to follow safe welding procedures and wear proper PPE (clothes, welding
helmet, safety glasses, welding gloves, boots, etc.).
