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Page 25For technical questions, please call 1-800-444-3353.SKU 68885
EXCESS PENETRATION OR
BURN-THROUGH
Weld droops on top and
underneath, or falls through
entirely, making a hole.
PROPER PENETRATION
Weld is visible underneath and
bulges slightly on top.
INADEQUATE PENETRATION
Weld does not contact the joint
fully, just on the surface.
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce wire feed speed.
Decrease weld current.
2. Welding speed too slow:
Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Maintain
1
/
2
″ or less stickout.
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
2. Insufficient weld heat:
Reduce welding speed.
Increase weld current.
3. Workpieces too thick/close:
Bevel thick workpieces, allow slight
gap, and weld in several passes.
4. Insufficient weld material:
Increase wire feed speed.
PROFILE VIEWS
Weld Problems
Penetration (Workpiece Heat Control)
Weld Not Adhering Properly
Gaps present between weld and previous bead or
between weld and workpiece. See areas below.
POSSIBLE CAUSES AND SOLUTIONS
1. Incorrect welding technique:
Place stringer bead at correct place in joint.
Adjust workpiece position or weld angle to permit
proper welding to bottom of piece.
Pause briefly at sides during weave bead.
Keep arc on leading edge of weld puddle.
Hold torch at proper angles.
2. Insufficient weld heat:
Increase current.
Increase wire feed speed.
3. Dirty workpiece:
Clean workpiece down to bare metal.
4. Insufficient weld material:
Increase wire feed speed.
PROFILE
VIEW
Bend at Joint
POSSIBLE CAUSES AND SOLUTIONS
1. Improper clamping:
Clamp workpieces securely.
Make tack welds to hold workpieces.
2. Excessive heat:
Weld a small portion and allow to cool before
proceeding.
Increase weld speed.
Reduce wire feed speed.
PROFILE
VIEW
Coat of Slag Over Weld
Slag is a necessary part of a flux-core wire
weld. It shields the weld from impurities.
Clean off the slag with the Chipping
Hammer and Wire Brush after welding.
Gas-shielded MIG welds are protected by the
shielding gas and do not need slag to protect them.
TOP
VIEW
PARTIALLY CHIPPED AWAY TO SHOW WELD
SAFETYMAINTENANCE BASIC WELDINGWELDING TIPS SETUP