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9-8.
Troubleshooting − Excessive Spatter
Possible Causes
Wire feed speed too high.
Voltage too high.
Electrode extension (stickout) too long.
Workpiece dirty.
Dirty welding wire.
9-9.
Troubleshooting − Porosity
Possible Causes
Dirty welding wire.
Workpiece dirty.
Welding wire extends too far out of nozzle.
9-10. Troubleshooting − Excessive Penetration
Excessive Penetration
Possible Causes
Excessive heat input.
9-11. Troubleshooting − Lack Of Penetration
Lack of Penetration
Possible Causes
Improper joint preparation.
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
Select lower wire feed speed.
Select lower voltage range.
Use shorter electrode extension (stickout).
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Good Penetration
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
Lack Of Penetration − shallow
fusion between weld metal and
base metal.
Good Penetration
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Corrective Actions
Corrective Actions
Corrective Actions
Corrective Actions
S-0636
S-0635
S-0639
S-0638
OM-923 Page 33
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Table of Contents
Troubleshooting
