Mma Welding Troubleshooting - Jasic EVOLVE 200 Operator's Manual

MMA WELDING TROUBLESHOOTING

Before starting any welding activity ensure that you have suitable eye protection and
protective clothing. Also take the necessary steps to protect any persons within the welding
area.
Arc welding defects and prevention methods
Defect
Excessive spatter (beads of metal
scattered around the weld area).
Uneven and erratic weld bead and
direction.
Lack of penetration – The weld bead
fails to create complete fusion
between material to be welded,
often surface appears okay but weld
depth is shallow.
Porosity – Small holes or cavities on
the surface or within the weld
material.
Excessive penetration – The weld
metal is below the surface level of
the material and hangs below.
Burning through – Holes within the
material where no weld exists.
Poor fusion – Failing of weld material
to fuse either with the material to be
welded or previous weld beads.
Possible cause
Amperage too high for the
selected electrode.
Voltage too high or arc length
too long.
Weld bead is inconsistent and
misses joint due to operator.
Poor joint preparation.
Insufficient heat input.
Poor weld technique.
Work piece dirty.
Electrode is damp.
Arc length is excessive.
Heat input too high.
Poor weld technique.
Heat input too high.
Insufficient heat level.
Poor welding technique.
Work piece dirty.
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Action
Reduce amperage or utilise larger
diameter electrode.
Reduce arc length or voltage.
Operator training required.
Joint design must allow for full access
to the root of the weld.
Material too thick.
Increase the amperage or increase the
electrode size and amperage.
Reduce travel speed.
Ensure the arc is on the leading edge of
the weld puddle.
Remove all contaminant from the
material i.e. oil, grease, rust, moisture
prior to welding.
Replace or dry the electrode.
Reduce the arc length.
Reduce the amperage or use a smaller
electrode and lower amperage.
Use correct welding travel speed.
Use lower amperage or smaller
electrode.
Use correct welding travel speed.
Increase the amperage or increase the
electrode size and amperage.
Joint design must allow for full access to
the root of the weld.
Alter welding technique to ensure
penetration such as weaving, arc
positioning or stringer bead technique.
Remove all contaminant from the
material i.e. oil, grease, rust, moisture
prior to welding.