Causes and Cures of

Common Welding Troubles

Porous Welds Cracked Welds Undercutting Distortion

Why Why Why Why
1. Excessively long or short arc length 1. Insufficient weld size 1. Faulty electrode manipulation 1. Improper tack welding and/or faulty joint
2. Welding current too high 2. Excessive joint restraint 2. Welding current too high preparation
3. Insufficient or damp shielding gas 3. Poor joint design and/or preparation 3. Too long an arc length 2. Improper bead sequence
4. Too fast travel speed 4. Filler metal does not match base metal 4. Too fast travel speed 3. Improper set-up and fixturing
5. Base metal surface covered with oil, grease, 5. Rapid cooling rate 5. Arc blow 4. Excessive Weld Size
moisture, rust, mill scale, etc. 6. Base metal surface covered with oil, grease, What to Do What to Do
6. Wet, unclean or damaged electrode moisture, rust, dirt or mill scale 1. Pause at each side of the weld bead when using 1. Tack weld parts with allowance for distortion
What to Do What to Do a weaving technique 2. Use proper bead sequencing
1. Maintain proper arc length 1. Adjust weld size to part thickness 2. Use proper electrode angles 3. Tack or clamp parts securely
2. Use proper welding current 2. Reduce joint restraint through proper design 3. Use proper welding current for electrode size 4. Make welds to specified size
and welding position
3. Increase gas flowrate and check gas purity 3. Select the proper joint design
4. Reduce arc length
4. Reduce travel speed 4. Use more ductile filler
5. Reduce travel speed
5. Properly clean base metal prior to welding 5. Reduce cooling rate through preheat
6. Reduce effects of arc blow
6. Properly maintain and store electrode 6. Properly clean base metal prior to welding

Spatter Lack of Fusion Overlapping Poor Penetration

Why Why Why
Why
1. Improper travel speed 1. Too slow travel speed 1. Travel speed too fast
1. Arc blow
2. Welding current too low 2. Incorrect electrode angle 2. Welding current too low
2. Welding current too high
3. Faulty joint preparation 3. Too large an electrode 3. Poor joint design and/or preparation
3. Too long an arch length
4. Too large an electrode diameter What to Do 4. Electrode diameter too large
4. Wet, unclean or damaged electrode
5. Magnetic arc blow 1. Increase travel speed 5. Wrong type of electrode
What to Do
6. Wrong electrode angle 2. Use proper electrode angles 6. Excessively long arc length
1. Attempt to reduce the effect of arc blow
What to Do 3. Use a smaller electrode size What to Do
2. Reduce welding current
1. Reduce travel speed 1. Decrease travel speed
3. Reduce arc length
2. Increase welding current 2. Increase welding current
4. Properly maintain and store electrodes
3. Weld design should allow electrode 3. Increase root opening or decrease root face
accessibility to all surfaces within the joint 4. Use smaller electrode
4. Reduce electrode diameter 5. Use electrode with deeper penetration
5. Reduce effects of magnetic arc blow characteristics
6. Use proper electrode angles 6. Reduce arc length

Magnetic Arc Blow Inclusions

Why
Why
1. Incomplete slag removal between passes
1. Unbalanced magnetic field during welding
2. Erratic travel speed
2. Excessive magnetism in parts or fixture
3. Too wide a weaving motion
What to Do
4. Too large an electrode
1. Use alternating current
5. Letting slag run ahead of arc
2. Reduce welding current and arc length
6. Tungsten spitting or sticking
3. Change the location of the work connection on
the workpiece What to Do
1. Completely remove slag between passes
2. Use a uniform travel speed
3. Reduce width of weaving technique
4. Use a smaller electrode size for better access to
joint
5. Increase travel speed or change electrode
angle or reduce arc length
6. Properly prepare tungsten and use proper
current