Troubleshooting − Excessive Penetration; Troubleshooting − Lack Of Penetration; Troubleshooting − Incomplete Fusion - Miller Electric M-10 Gun Owner's Manual

8-10. Troubleshooting − Excessive Penetration
Excessive Penetration
Possible Causes
Excessive heat input.
Wrong polarity.
8-11. Troubleshooting − Lack Of Penetration
Lack of Penetration
Possible Causes
Improper joint preparation.
Improper weld technique.
Insufficient heat input.
Wrong polarity.
8-12. Troubleshooting − Incomplete Fusion
Possible Causes
Workpiece dirty.
Insufficient heat input.
Improper welding technique.
Wrong polarity.
OM-1328 Page 36
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Good Penetration
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
Configure polarity as shown in Section 4-4. Always read and follow wire manufacturer's
recommended polarity, and see Section 4-3.
Lack Of Penetration − shallow
fusion between weld metal and
base metal.
Good Penetration
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Configure polarity as shown in Section 4-4. Always read and follow wire manufacturer's
recommended polarity, and see Section 4-3.
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Select higher voltage range and/or adjust wire feed speed.
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.
Use correct gun angle of 0 to 15 degrees.
Configure polarity as shown in Section 4-4. Always read and follow wire manufacturer's
recommended polarity, and see Section 4-3.
Corrective Actions
Corrective Actions
Corrective Actions
S-0639
S-0638
S-0637