Flux Cored Arc Welding

Weld Troubleshooting
Guide

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Copyright  2004 Lincoln Global Inc.
 Wire Burnback
Possible Causes Corrective Actions
* Drive Rolls in Poor Condition * Tighten, Clean, or Replace Drive
Rolls
* Excessive Welding Voltage * Reduce Voltage
* Insufficient Electrical Stickout * Increase Contact Tip to Work
Piece Distance
* Contact Tip in Poor Condition * Clean or Replace Contact Tip
* Liner in Poor Condition * Blow Out Liner with Compressed
Air or Replace Liner
* Excessive Burn-back Time * Reduce Burn-back Time
* Spatter on Contact Tip * Remove Spatter at Regular
Intervals of Time, Use Anti-Spatter
Compounds in Gun

Copyright  2004 Lincoln Global Inc.

 Inconsistent Arc Starting
Possible Causes Corrective Actions
* Excessive Run-In Speed * Reduce Run-In Speed
* Excessive Welding Amperage * Reduce Amperage (WFS)
* Insufficient Welding Voltage * Increase Voltage
* Excessive Electrical Stickout * 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
* Contaminants on Base Material * Clean Work Piece Prior to
Welding

Copyright  2004 Lincoln Global Inc.

 Burnthrough
Possible Causes Corrective Actions
* Excessive Amperage * Reduce Amperage (WFS)
* Poor Joint Fit-Up (Excessive * Reduce Root Openings or Gaps
Gap)
* Improper Travel Angle * Use a Push Angle
* Travel Speed Too Low * Increase Travel Speed or Speed
of Positioner
* Improper Shielding Gas * Use a Lower Percentage of CO2
(FCAW-GS Only) Shielding Gas (Use Argon Mix)
* Insufficient Electrical Stickout * Increase Contact Tip to Work
Piece Distance

Copyright  2004 Lincoln Global Inc.

 Incomplete Penetration
Possible Causes
* Insufficient Amperage
* Improper Travel Angle
* Excessive Electrical Stickout * Decrease Contact Tip to Work
* Improper Shielding Gas
(FCAW-GS Only)
* Improper Wire Selection
Wire/Consult
* Weld Joint Too Narrow
Weld
Corrective Actions
* Increase Amperage (WFS)
* Use Less of a Drag Angle
Piece Distance
* Use a Shielding Gas With a
Higher Percentage of CO2
* Choose the Correct
the Manufacturer if Necessary
* Increase the Opening of the
Joint
Copyright  2004 Lincoln Global Inc.
 Distortion
Possible Causes Corrective Actions
* Excessive Amperage * Decrease Amperage (WFS)
* Uneven Heating of Work Piece * Distribute Heat Evenly Over Both
Pieces of Metal Being Welded
* Improper Welding Procedures * Consult Manufacturer’s
Recommendations
* Improper Electrode Selection * Consult the Manufacturer for
Proper Wire Selection

Copyright  2004 Lincoln Global Inc.

 Excessive Spatter
Possible Causes
* Excessive Welding Voltage
* Insufficient Electrical Stickout * Increase Contact Tip to Work
* Improper Shielding Gas
(FCAW-GS Only)
* Excessive Gas Flow Rate
(FCAW-GS Only)
* Contaminants on Base Material
* Contact Tip Recessed Too Much
Corrective Actions
* Reduce Voltage
* Use a Higher Percentage of
Argon in the Shielding Gas
* Reduce Gas Flow Rate
* Clean the Work Piece Prior to
Welding
* Use Longer Contact Tip, Shorter
Nozzle, or Adjustable Nozzle
Copyright  2004 Lincoln Global Inc.
 Porosity
Possible Causes Corrective Actions
* Inadequate Gas Coverage * Increase Flow Rate if Too Low
(FCAW-GS Only) * Eliminate Drafts that Can Disrupt
the Shielding Gas Coverage
* Ensure that Hoses are in Good
Repair & Connections are tight
* Excessive Electrical Stickout * Decrease Contact Tip to Work
(FCAW-GS Only) Piece Distance
* Contaminants on Base Material * Use a Higher Deoxidizing Wire
* Clean Base Material
* Insufficient Electrical Stickout * Increase Electrical Stickout to
(FCAW-SS Only) Prevent Premature Activation of
Core Elements

Copyright  2004 Lincoln Global Inc.

 Convex Weld Bead
Possible Causes Corrective Actions
* Insufficient Welding Voltage * Increase Voltage
* Excessive Amperage * Reduce Amperage (WFS)
* Excessive Travel Speed * Reduce Travel Speed or Speed
of Positioner
* Improper Gun Angle * Reduce Drag Angle
* Excessive Electrical Stickout * Decrease Contact Tip to Work
Piece Distance
* Improper Polarity * Ensure Proper Polarity: DC+ for
Outershield, DC- for most
Innershield
* Improper Shielding Gas * Use a Higher Percentage of
(FCAW-GS Only) Argon in the Shielding Gas

Copyright  2004 Lincoln Global Inc.

 Concave Weld Bead or Undercut
Possible Causes Corrective Actions
* Excessive Welding Voltage * Reduce Voltage
* Insufficient Amperage * Increase Amperage (WFS)
* Excessive Travel Speed * Decrease Travel Speed or Speed
of Positioner
* Improper Gun Angle * Increase Drag Angle
* Poor Electrode Manipulation * 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
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Corrective Actions
* Reduce Amperage (WFS)
* Reduce Voltage
* Increase Drag Angle
* Reduce Travel Speed or Speed
of Positioner
* Increase Corner Joint Angle
Copyright  2004 Lincoln Global Inc.
 Solidification Cracking
Possible Causes Corrective Actions
* Improper Technique in Crater * Increase Crater Fill Time
* Reduce WFS During Crater Fill
* Insufficient Weld Bead Size * Decrease Travel Speed
Concave Weld(Restraint Crack) * Decrease Travel Angle
* “Tramp” Elements in Base * Reduce Amperage (WFS)
Material
* Insufficient Preheat in Certain * Increase Preheat Time and/or
Base Materials (i.e. High Carbon) Temperature
* Cooling Rate of Weld Too Fast * Insulate/Slow Cool Weld
* Excessive Contaminants on Base * Clean Work Piece Prior to
Material Welding

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Copyright  2004 Lincoln Global Inc.

 FCAW-GS Gas Marks
Possible Causes Corrective Actions
* Excessive Contaminants on * Clean Work Piece Prior to
Base Material Welding
* Excessive “Lube” on Filler * Clean Filler Wire Prior to Welding
Material
* “Tramp” Elements in Base * Reduce Amperage (WFS)
Material
* Excessive Electrical Stickout * Reduce Contact Tip to Work
Distance
* Too Much Argon in Shielding * Use 100% Carbon Dioxide
Gas
* Excessive Welding Voltage * Reduce Welding Voltage

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Copyright  2004 Lincoln Global Inc.