Stick Welding Troubleshooting - Pro-Tec Welding PRO-TEC 215 MP Operating Manual

TROUBLESHOOTING and MAINTENANCE

6.2 STICK Welding Troubleshooting

NOTE 21: Weld quality is dependent on the correct consumables, proper welding technique and equipment maintenance
Description
1. Porosity: gas holes or voids in weld
metal.
2. Crack occurring in weld metal soon
after solidification commences.
3. A gap is left by failure of the weld metal
to fill the root of the weld.
4. Portions of the weld run do not fuse to
the surface of the metal or edge of the
joint
5. Non-metallic particles are trapped in the
weld metal (slag inclusion).
Difficult to establish an arc.
6.
7. The arc wanders away from the
joint during welding (Arc Blow).
Operating Manual No: PWOM-215/250MP-001
Possible Cause
A Electrodes are damp.
B Welding Amperage is too high.
C Surface impurities such as oil, grease,
paint, etc.
A Rigidity of joint.
B Insufficient throat thickness.
C Cooling rate is too high.
A Welding Amperage is too low.
B Electrode too large for joint.
C Insufficient gap.
D Incorrect sequence.
A Small electrodes used on heavy cold
plate.
B Welding Amperage is too low.
C Wrong electrode angle.
D Travel speed of electrode is too high.
E Scale or dirt on joint surface.
A Non-metallic particles may be trapped in
undercut from previous run.
B Joint preparation too restricted.
C Irregular deposits allow slag to be
trapped.
D Lack of penetration with slag trapped
beneath weld bead.
E Rust or mill scale is preventing full
fusion.
F Wrong electrode for position in which
welding is done.
A Loose connections in welding leads.
B Metal is contaminated with oil or rust or
grease or dirt.
A Air movement is pushing the arc.
B The coating on the stick electrode isn't
even around the metal core.
C Welding Amperage passing thru the
metal sets up a magnetic field which
pushes the arc.
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Remedy
A Dry electrodes before use.
B Reduce Welding Amperage.
C Clean joint before welding
A Redesign to relieve weld joint of severe
stresses or use crack resistance electrodes.
B Travel slightly slower to allow greater build
up in throat.
C Preheat plate and cool slowly.
A Increase Welding Amperage
B Use smaller diameter electrode.
C Allow wider gap.
D Use correct build-up sequence.
A Use larger electrodes and pre-heat the plate.
B Increase Welding Amperage
C Adjust angle so the welding arc is directed
more into the base metal
D Reduce travel speed of electrode
E Clean surface before welding.
A If bad undercut is present, clean slag out and
cover with a run from a smaller diameter
electrode.
B Allow for adequate penetration and room for
cleaning out the slag.
C If very bad, chip or grind out irregularities.
D Use smaller electrode with sufficient amper-
age to give adequate penetration. Use suita-
ble tools to remove all slag from corners.
E Clean joint before welding.
F Use electrodes designed for position in
which welding is done, otherwise proper
control of slag is difficult.
A Check all welding leads electrical connec-
tions for defects like burnt or discoloration
connections. Replace/replace electrical con-
nections or welding leads.
B Clean metal to remove contamination.
A Shield the weld zone from the air movement.
B Use a new electrode from another batch.
C Reposition the Earth Clamp position to re-
duce this affect.
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