Mma (Stick) Welding Trouble Shooting - Unimig VIPER Operating Manual

MMA (STICK) WELDING TROUBLE
SHOOTING
The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction, the manufacturer's recommendations
should be strictly adhered to and followed.
1: No arc
Possible Reason
Incomplete welding circuit
Wrong mode selected
No power supply
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Reason
Arc length too long
Work piece dirty, contaminated or moisture
Damp electrodes
3: Excessive Spatter
Possible Reason
Amperage too high
Arc length too long
3: Weld sits on top, lack of fusion
Possible Reason
Insufficient heat input
Work piece dirty, contaminated or moisture
Poor welding technique
4: Lack of penetration
Possible Reason
Insufficient heat input
Poor welding technique
Poor joint preparation
5: Excessive penetration - burn through
Possible Reason
Excessive heat input
Incorrect travel speed
6: Uneven weld appearance
Possible Reason
Unsteady hand, wavering hand
7: Distortion − movement of base metal during welding
Possible Reason
Excessive heat input
Poor welding technique
Poor joint preparation and or joint design
7: Electrode welds with different or unusual arc characteristic
Possible Reason
Incorrect polarity
Suggested Remedy
Check earth lead is connected. Check all cable connections.
Check the MMA selector switch is selected
Check that the machine is switched on and has a power supply
Suggested Remedy
Shorten the arc length
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal
Use only dry electrodes
Suggested Remedy
Decrease the amperage or choose a larger electrode
Shorten the arc length
Suggested Remedy
Increase the amperage or choose a larger electrode
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from base metal
Use the correct welding technique or seek assistance for the correct technique
Suggested Remedy
Increase the amperage or choose a larger electrode
Use the correct welding technique or seek assistance for the correct technique
Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the
correct joint design and fit up
Suggested Remedy
Reduce the amperage or use a smaller electrode
Try increasing the weld travel speed
Suggested Remedy
Use two hands where possible to steady up, practise your technique
Suggested Remedy
Reduce the amperage or use a smaller electrode
Use the correct welding technique or seek assistance for the correct technique
Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the
correct joint design and fit up
Suggested Remedy
Change the polarity, check the electrode manufacturer for correct polarity
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