Gas Metal Arc Welding

Weld Troubleshooting Guide

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Copyright 2004 Lincoln Global Inc.

Wire Burnback
Possible Causes
* Drive Rolls in Poor Condition * Excessive Welding Voltage * Insufficient Electrical Stickout * Contact Tip in Poor Condition * Liner in Poor Condition * Excessive Burn-back Time * Spatter on Contact Tip

Corrective Actions
*Tighten, Clean, or Replace Drive Rolls * Reduce Voltage * Increase Contact Tip to Work Piece Distance * Clean or Replace Contact Tip * Blow Out Liner with Compressed Air or Replace Liner * Reduce Burn-back Time * Remove Spatter at Regular Intervals of Time, Use Anti-Spatter Compounds in Gun

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Copyright 2004 Lincoln Global Inc.

Inconsistent Arc Starting

Possible Causes
* Excessive Run-In Speed * Excessive Welding Amperage * Insufficient Welding Voltage * Excessive Electrical Stickout

Corrective Actions

*Reduce Run-In Speed * Reduce Amperage (WFS) * Increase Voltage * Decrease Contact Tip to Work Piece Distance * Contact Tip in Poor Condition * Clean or Replace Contact Tip * Poor Work Piece Connection * Tighten Work Piece Connection or in Poor Condition or Replace Cables * Excessive Inductance/Insufficient * Decrease Inductance Control Pinch Control * Contaminants on Base Material * Clean Work Piece Prior to Welding

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Copyright 2004 Lincoln Global Inc.

Burnthrough
Possible Causes
* Excessive Amperage * Poor Joint Fit-Up (Excessive Gap * Improper Travel Angle * Travel Speed Too Low

Corrective Actions
*Reduce Amperage (WFS) * Reduce Root Openings or Gaps

* Use a Push Angle * Increase Travel Speed or Speed of Positioner * Improper Shielding Gas * Use a Lower Percentage of CO2 in Shielding Gas (Use Argon Mix) * Improper Mode of Metal Transfer * Use Short Circuit Mode of Metal Transfer * Insufficient Electrical Stickout * Increase Contact Tip to Work Piece Distance

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Copyright 2004 Lincoln Global Inc.

Incomplete Penetration
Possible Causes
* Insufficient Amperage * Improper Travel Angle * Excessive Electrical Stickout

Corrective Actions

*Increase Amperage (WFS) * Use Less of a Drag Angle * Decrease Contact Tip to Work Piece Distance * Improper Shielding Gas * Use a Shielding Gas With a Higher Percentage of CO2 * Improper Wire Selection * Choose the Correct Wire/Consult the Manufacturer if Necessary * Improper Mode of Metal Transfer * Use Spray Arc or Pulse Spray Arc Mode of Metal Transfer * Weld Joint Too Narrow * Increase the Opening of the Weld Joint

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Copyright 2004 Lincoln Global Inc.

Distortion
Possible Causes
* Excessive Amperage * Uneven Heating of Work Piece

Corrective Actions

* Decrease Amperage (WFS) * Distribute Heat Evenly Over Both Pieces of Metal Being Welded * Improper Welding Procedures * Consult Manufacturers Recommendations * Improper Mode of Metal Transfer * Use Short Circuit Mode of Metal Transfer

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Copyright 2004 Lincoln Global Inc.

Excessive Spatter
Possible Causes
* Excessive Welding Voltage * Insufficient Inductance/Slope * Insufficient Electrical Stickout * Improper Shielding Gas

Corrective Actions

* Reduce Voltage * Increase Inductance (Add Droop) * Increase Contact Tip to Work * Use a Higher Percentage of Argon in the Shielding Gas * Excessive Gas Flow Rate * Reduce Gas Flow Rate * Contaminants on Base Material * Clean the Work Piece Prior to Welding * Contact Tip Recessed Too Much * Use Longer Contact Tip, Shorter Nozzle, or Adjustable Nozzle

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Copyright 2004 Lincoln Global Inc.

Porosity
Possible Causes
* Inadequate Gas Coverage

Corrective Actions
* Increase Flow Rate if Too Low * Decrease Flow Rate if Weld Turbulence Occurs * Eliminate Drafts that Can Disrupt the Shielding Gas Coverage * Ensure that Hoses are in Good Repair & Connections are tight * Decrease Contact Tip to Work Piece Distance * Use a Higher Deoxidizing Wire and/or Clean Base Material * Eliminate Leaks in Gas Lines * Store and Handle Electrodes Properly
Copyright 2004 Lincoln Global Inc.

* Excessive Electrical Stickout

* Contaminants on Base Material * Contaminated Shielding Gas or Electrode
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Convex Weld Bead

Possible Causes
* Insufficient Welding Voltage * Excessive Amperage * Excessive Travel Speed * Improper Gun Angle * Excessive Electrical Stickout

Corrective Actions
* Increase Voltage * Reduce Amperage (WFS) * Reduce Travel Speed or Speed of Positioner * Reduce Drag Angle * Decrease Contact Tip to Work Piece Distance * Ensure DC+ Polarity * Use a Higher Percentage of Argon in the Shielding Gas * Increase Inductance Control

* Improper Polarity * Improper Shielding Gas

* Insufficient Inductance

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Copyright 2004 Lincoln Global Inc.

Concave Weld Bead / Undercut

Possible Causes
* Excessive Welding Voltage * Insufficient Amperage * Excessive Travel Speed * Improper Gun Angle * Poor Electrode Manipulation

Corrective Actions
* Reduce Voltage * Increase Amperage (WFS) * Decrease Travel Speed or Speed of Positioner * Increase Drag Angle * Improve Technique/Hold the Corners in Out-of-Position Welding

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Copyright 2004 Lincoln Global Inc.

Arc Blow
Possible Causes
* Excessive Amperage * Excessive Welding Voltage * Improper Gun Angle * Excessive Travel Speed * Improper Joint Design

Corrective Actions
* Reduce Amperage (WFS) * Reduce Voltage * Increase Drag Angle * Reduce Travel Speed or Speed of Positioner * Increase Corner Joint Angle

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Copyright 2004 Lincoln Global Inc.

Solidification Cracking
Possible Causes
* Improper Technique in Crater * Insufficient Weld Bead Size Concave Weld(Restraint Crack) * Tramp Elements in Base Material * Insufficient Preheat in Certain Base Materials (i.e. High Carbon) * Cooling Rate of Weld Too Fast * Excessive Contaminants on Base Material

Corrective Actions
* Increase Crater Fill Time * Reduce WFS During Crater Fill * Decrease Travel Speed * Decrease Travel Angle * Reduce Amperage (WFS) * Increase Preheat Time and/or Temperature * Insulate/Slow Cool Weld * Clean Work Piece Prior to Welding

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Copyright 2004 Lincoln Global Inc.