Harbor Freight Tools Vulcan Migmax 215 Owner's Manual & Safety Instructions page 57

Weld Problems
Penetration (Workpiece Heat Control)
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath, or falls through
entirely, making a hole.
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce wire feed speed.
Decrease weld current.
2. Travel speed too slow:
Increase travel speed and ensure
that travel speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.
Bend at Joint
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase travel speed.
Reduce wire feed speed.
Coat of Slag Over Weld
TOP
VIEW
PARTIALLY CHIPPED AWAY TO SHOW WELD
Slag is a necessary part of a flux-cored wire
weld. It shields the weld from impurities.
Clean off the slag with a Chipping Hammer
and Wire Brush after welding.
Gas-shielded MIG welds are protected by the
shielding gas and do not need slag to protect them.
Item 63617
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
PROFILE VIEWS
For technical questions, please call 1-888-380-0318.
INADEQUATE PENETRATION
Weld does not penetrate the
joint fully, just on the surface.
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Maintain 1/2" or less CTWD.
Keep arc on leading edge of weld puddle.
Hold MIG Gun at proper angles.
2. Insufficient weld heat:
Reduce travel speed.
Increase weld current.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase wire feed speed.
Weld Not Adhering Properly
Gaps present between weld and previous bead or
between weld and workpiece. See areas below.
PROFILE
VIEW
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold MIG Gun at proper angles.
2. Insufficient weld heat:
Increase current.
Increase wire feed speed.
3. Dirty workpiece:
Clean workpiece down to bare metal.
4. Insufficient weld material:
Increase wire feed speed.
5. Workpiece gap too narrow:
Widen groove or increase bevel.
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