Welding Faults - Welding Industries Malaysia WIM200 Instruction Manual

10.0 WELDING FAULTS

FAULT
1 Weld deposit 'stringy' and incomplete
2 Weld deposit too thick
3 Arc unstable excessive spatter and
weld porosity
4 Wire repeatedly burns back
5 Burning holes in the workpiece
6 Lack of penetration
Metal
Mild Steel
Aluminium
Stainless Steel
Copper, Nickel and Alloys
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POSSIBLE CAUSE AND REMEDY
1 a Torch moved over workpiece too quickly
1 b Gas mixture incorrect
2 a Torch moved over workpiece too slowly
2 b Welding voltage too low
3 a Torch held too far from the workpiece
3 b Rust grease or paint on workpiece
3 c Insufficient shielding gas; check gas contents
gauge, regulator setting and operation of gas
valve
4 a Torch held too close to the workpiece
4 b Intermittent break in the welding circuit caused
by:
(1) Contact tip loose-tighten
(2) Contact tip damaged-replace
(3) Welding wire or liner corroded-replace
wire or liner
4 c Wire feed slipping caused by:
(1) Restriction in liner (such as kinks) or
contact tip-check and replace if necessary
(2) Worn-out feed rolls-replace
(3) Guide tube or pressure roll alignments
incorrect.
5 a Torch moved too slowly or erratically
5 b Welding volts too high
5 c Wire feed speed too high
6 a Torch moved too fast
6 b Welding volts too low
6 c Wire feed speed too low
SHIELDING GAS TABLE
MIG WELDING
Gas
CO2
Argon + CO2
Argon + CO2 + Oxygen
Argon
Argon Helium
Argon + CO2 + Oxygen
Argon + Oxygen
Argon
Argon Helium
Remarks
Argon controls spatter
Oxygen improves arc stability
Stable Arc-Sound welds
Higher heat input
Suitable for heavy sections
Arc stability
Minimum spatter
Suitable for light gauges
Higher heat input
Suitable for heavy sections
V1.1.06