Troubleshooting Common Welding Problems

Troubleshooting common welding problems is a necessary part of developing welding proficiency. At MuggyWeld, we believe that every weld should be a good weld. While we ensure that the utmost care and correct welding technique is used and the right amount of welding metal is deposited, some welders practice poor welding habits which result in faults and common welding problems.

Undercut Resulting In Stress And Fatigue Crack

Several factors can cause this welding problem. These include high welding current, oversized electrode diameter, incorrect electrode positioning, and poor electrode manipulation. You can fix it in a few ways. Try using a smaller diameter electrode or lowering the welding current. Also, correct the electrode position and avoid forming a large molten weld puddle. Each of these steps helps troubleshoot the issue.

Unpleasing Weld Spatter

While this common problem does not affect the structure, it is not aesthetically pleasing. This generally happens from the use of the incorrect wrong electrode along with too high a welding current. Alternatively, it is caused by the wrong polarity or an ill-sized electrode. To troubleshoot this problem, use the correct current setting, check for inherent spatter on the electrode, use the correct polarity, and an electrode sporting the correct diameter.

Poor Weld Appearance

Caused by the failure to clean the finished weld deposit, poor welding technique, improper joint preparation, and electrode manipulation, among other reasons, this common welding problem can be troubleshot by removing all flux, slag, and spatter from the base metal or weld bead. Should this not fix the problem, we recommend that proper joint preparation is used as well as a correct technique and appropriately sized electrode.

Structural Failure From Incomplete Penetration

Incomplete penetration is another common welding problem. It often results from welding too quickly, poor joint preparation, oversized electrodes, or low welding current. You can fix it in several ways. Slow down the welding speed. Ensure there’s a proper gap at the bottom of the joint. Use enough welding current to achieve full penetration.

Poor Fusion

Another welding problem is poor fusion which is caused by improper current settings, welding techniques, insufficient joint preparation, and ill-sized welding electrodes. To troubleshoot this problem, it is advised to use sufficient high welding currents as well as widened weaves and a small electrode.

Distorted Weldment

To return to a desired state after distortion, care needs to be taken as well as proper design. When a welder fails to control the welding heat or fails to follow an improper welding sequence, distortion occurs. To troubleshoot this problem, study the structure and define a proper welding sequence. Then be sure to properly align the various parts and distribute the welding heat. Pre-form the parts sufficiently and clamp or tack weld the parts.

Plate Warping And Structural Weakening

This common welding problem happens due to poor joint preparation, incorrect welding procedures, improper clamping, or excessive local heat. To troubleshoot it, prepare the joint carefully and use a back-step or skip-sequence welding method. Clamp the parts near the joint securely. Weld quickly using a high-speed electrode with moderate penetration.

Troubleshooting Common Welding Problems