Troubleshooting − Burn-Through; Troubleshooting − Waviness Of Bead; Troubleshooting − Distortion - Miller MILLERMATIC 135 Owner's Manual

8-13. Troubleshooting − Burn-Through
Possible Causes
Excessive heat input.
Wrong polarity.
8-14. Troubleshooting − Waviness Of Bead
Possible Causes
Welding wire extends too far out of nozzle.
Unsteady hand.
8-15. Troubleshooting − Distortion
Possible Causes
Excessive heat input.
OM-1324 Page 38
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer's
recommended polarity, and see Section 4-4.
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Support hand on solid surface or use two hands.
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
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Corrective Actions
Corrective Actions
Corrective Actions
S-0640
S-0641
S-0642