MIG (GMAW) Troubleshooting: Excessive Spatter
Excessive spatter is a scatter of molten metal particles around the weld.
MIG Excessive Spatter Reasons
- Voltage too high
- Not enough shielding gas
- Dirty workpiece
- Dirty filler wire
- High current or fast wire feed
MIG Excessive Spatter Remedy
- Reduce Voltages
- Increase flow of shielding gas
- Clean workpiece from dirt and oil
- Use clean filler wire
- Reduce feed of filler wire
MIG (GMAW) Troubleshooting: Irregular Beat
Weld is wavy and not parallel to the joint.
MIG Irregular Beat Reasons
- The stickout is too long
- Not enough control with one hand
MIG Irregular Beat Remedy
- Stickout must be less then 13mm
- Use 2 hand if needed
MIG (GMAW) Troubleshooting: Burn Trough
Weld melts metal completely producing a hole.
MIG Irregular Burn Trough Reasons
- Too much heat
- Defective equipment
MIG Irregular Burn Trough Remedy
- Reduce voltage
- increase travel speed steadily
MIG (GMAW) Troubleshooting: Lack of Weld Penetration
Weld does not completely penetrate the joint.
MIG Lack of Weld Penetration Reasons
- Insufficient heat
- Incorrect welding technique
MIG Irregular Burn Trough Remedy
- Increase voltage, wire speed or reduce travel speed
- Keep arc on the leading edge of the weld puddle
- Use correct torch angle (0-15 degrees)
MIG (GMAW) Troubleshooting: Porosity
Cavities exist in the weld.
MIG Porosity Reasons
- Insufficient shielding gas coverage
- Electrode length (stickout) too long
- Workpiece or filler wire dirty
MIG Porosity Remedy
- Increase shielding gas flow
- Ensure electrode extends no more than 13mm
- Ensure to work on clean workpiece with clean filler wire