Saturday, September 5, 2015

WELDING PROBLEMS & SOLUTIONS

 

In this post, we will briefly see some commonly occuring Welding Defects and their Solutions.


WELDING DEFECTS

CAUSES

SOLUTIONS
Porosity
 
Wrong current setting
Excessive speed
Dirt or impurities in base metal
Set proper current
Reduce speed of travel
Use shallow penetration electrode.
Spatter
Amperage (heat) too high
Excessive arc length
.Arc Blow
Wrong polarity
Reduce amperage
Shorten arc
Direct travel to the direction of blow.
Switch to opposite
Arc Hard to Start
Current setting too low
Poor or no ground
Work dirty
Low input line voltage
Broken cable
Corroded holder jaws
Increase current (Amperage)
Attach ground to clean area of metal
Remove rust, paint, oxides
Check line voltage
Usually in holder or ground- replace cable
File and clean them up nicely
Slag Inclusions
Current setting too low
Too short an arc
Wrong bead forming procedure
 
Increase amperage
Increase arc length
Correct to proper waving bead (Welder Skills)
Poor Fusion
Current setting too low
Wrong manipulation
Too long an arc
Incorrect work preparation
Reset current
Correct speed and change weave
Shorten arc length to frying sound
Clean and prepare weld joint (V Joint)
Undercut
Current amperage too high
Travel speed too fast
Arc length excessive
Incorrect electrode to work angle
Wrong diameter electrode
Lower amperage
Reduce welding travel speed
Shorten arc length
Use correct electrode angle (Welder Skills)
Increase electrode diameter one size
Distortion
 
Improper set-up and jigging
Excessive heating of weld area
Wrong welding procedure
 
Correct set-up or jigging design
Reduce heat in work
Use correct welding procedure
Use back step welding
Cracking
 
High carbon or poor quality material
Wrong bead configuration
Improper selection of electrode type
Too fast cooling
Preheat
Avoid excessive heat and puddle size
Check and use correct type of electrode
Preheat and post-heat,  Cool slowly

 

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