Mig (Gmaw/Fcaw) Welding Troubleshooting - ESAB CIGWELD WeldSkill 185LCD Operating Manual

WeldSkill 185LCD

5.14 MIG (GMAW/FCAW) Welding Troubleshooting

Solving Problems Beyond the Welding Terminals
The general approach to fix Gas Metal Arc Welding (GMAW) problems is to start at the wire spool then
work through to the MIG torch. There are two main areas where problems occur with GMAW, Porosity and
Inconsistent wire feed
Solving Problems Beyond the Welding Terminals - Porosity
When there is a gas problem the result is usually porosity within the weld metal. Porosity always stems from
some contaminant within the molten weld pool which is in the process of escaping during solidification of
the molten metal. Contaminants range from no gas around the welding arc to dirt on the work piece surface.
Porosity can be reduced by checking the following points.
FAULT
1 Shielding gas cylinder contents
and flow meter.
2 Gas leaks.
3 Internal gas hose in the Power
Source.
4 Welding in a windy environment.
5 Welding dirty, oily, painted,
oxidised or greasy plate.
6 Distance between the MIG torch
nozzle and the work piece.
7 Maintain the MIG torch in good
working order.
Table 5-2: Solving Problems beyond the Welding Terminals-Porosity
WARNING
! !
Disengage the feed roll when testing for gas flow by ear.
MIG (GMAW) WELDING
Ensure that the shielding gas cylinder is not empty and the
flow meter is correctly adjusted to 15 litres per minute.
Check for gas leaks between the regulator/cylinder connection
and in the gas hose to the Power Source.
Ensure the hose from the solenoid valve to the torch adaptor
has not fractured and that it is connected to the torch adaptor.
Shield the weld area from the wind or increase the gas flow.
Clean contaminates off the work piece.
Keep the distance between the MIG torch nozzle and the work
piece to a minimum. Refer to Section 5.11
A Ensure that the gas holes are not blocked and gas is exiting
out of the torch nozzle.
B Do not restrict gas flow by allowing spatter to build up inside
the torch nozzle.
C Check that the MIG torch O-rings are not damaged.
5-18
CAUSE
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