Miller Bobcat 225 Owner's Manual page 69

Possible Causes
Amperage too high for electrode.
Arc length too long or voltage too high.
Possible Causes
Insufficient heat input.
Improper welding technique.
Workpiece dirty.
Possible Causes
Improper joint preparation.
Improper weld technique.
Insufficient heat input.
Possible Causes
Excessive heat input.
Possible Causes
Excessive heat input.
Possible Causes
Unsteady hand.
Excessive Spatter - scattering of molten metal particles that cool to solid form near weld bead.
Decrease amperage or select larger electrode.
Reduce arc length or voltage.
Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceding
weld bead.
Increase amperage. Select larger electrode and increase amperage.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Lack Of Penetration - shallow fusion between weld metal and base metal.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Keep arc on leading edge of weld puddle.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration - weld metal melting through base metal and hanging underneath
weld.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through - weld metal melting completely through base metal resulting in holes where no
metal remains.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead - weld metal that is not parallel and does not cover joint formed by base
metal.
Use two hands. Practice technique.
Corrective Actions
Corrective Actions
Corrective Actions
Corrective Actions
Corrective Actions
Corrective Actions
OM-286503 Page 65