Troubleshooting Your MIG Weld

Your MIG welding bead offers insight for troubleshooting…

Most common welding problems fall into four categories:

  1. Weld porosity
  2. Improper weld bead profile
  3. Lack of fusion
  4. Faulty wire delivery related to equipment setup and maintenance

The following chart illustrates some common weld bead distortions, and their likely cause:

  1. Good weld bead
  2. Voltage too high; inconsistent penetration of base material; turbulent weld pool
  3. Voltage too low; poor starts, control, penetration; convex bead, poor tie-in of weld, excessive splatter
  4. Low shielding/long stickout; porosity, pinholes in face/interior of weld indicate low shielding gas, excess stickout; possible surface issues
  5. Travel speed too fast; narrow convex bead, poor tie-in, insufficient penetration and weld bead
  6. Travel speed too slow; excessively wide bead, poor penetration; potential burn-through on thinner material
  7. Wire feed speed/Amp too high; poor arc starts, wide weld bead, burn-through, distortion; caused by wire speed, or Amp setting
  8. Wire feed speed/Amp too low; narrow, often convex bead, poor tie-in; caused by wire speed, or Amp setting

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