Download - GMAW Troubleshooting Guide
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11Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Gas Metal Arc WeldingGas Metal Arc Welding
Weld Troubleshooting Weld Troubleshooting GuideGuide
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Drive Rolls in Poor Condition* Drive Rolls in Poor Condition*Tighten, Clean, or Replace Drive*Tighten, Clean, or Replace Drive
RollsRolls
* Excessive Welding Voltage* Excessive Welding Voltage * Reduce Voltage* Reduce Voltage
* Insufficient Electrical Stickout* Insufficient Electrical Stickout * Increase Contact Tip to Work* Increase Contact Tip to Work
Piece DistancePiece Distance
* Contact Tip in Poor Condition* Contact Tip in Poor Condition * Clean or Replace Contact Tip* Clean or Replace Contact Tip
* Liner in Poor Condition* Liner in Poor Condition * Blow Out Liner with Compressed* Blow Out Liner with Compressed
Air or Replace LinerAir or Replace Liner
* Excessive Burn-back Time* Excessive Burn-back Time * Reduce Burn-back Time* Reduce Burn-back Time
* Spatter on Contact Tip* Spatter on Contact Tip * Remove Spatter at Regular * Remove Spatter at Regular
Intervals of Time, Use Anti-SpatterIntervals of Time, Use Anti-Spatter
Compounds in GunCompounds in Gun
Wire BurnbackWire Burnback
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Excessive Run-In Speed * Excessive Run-In Speed *Reduce Run-In Speed*Reduce Run-In Speed
* Excessive Welding Amperage* Excessive Welding Amperage * Reduce Amperage (WFS)* Reduce Amperage (WFS)
* Insufficient Welding Voltage* Insufficient Welding Voltage * Increase Voltage* Increase Voltage
* Excessive Electrical Stickout* Excessive Electrical Stickout * Decrease Contact Tip to Work* Decrease Contact Tip to Work
Piece DistancePiece Distance
* Contact Tip in Poor Condition* Contact Tip in Poor Condition * Clean or Replace Contact Tip* Clean or Replace Contact Tip
* Poor Work Piece Connection * Poor Work Piece Connection * Tighten Work Piece Connection* Tighten Work Piece Connection
or in Poor Condition or in Poor Condition or Replace Cables or Replace Cables
* Excessive Inductance/Insufficient* Excessive Inductance/Insufficient * Decrease Inductance Control* Decrease Inductance Control
Pinch ControlPinch Control
* Contaminants on Base Material* Contaminants on Base Material * Clean Work Piece Prior to * Clean Work Piece Prior to
WeldingWelding
Inconsistent Arc StartingInconsistent Arc Starting
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Excessive Amperage* Excessive Amperage *Reduce Amperage (WFS)*Reduce Amperage (WFS)
* Poor Joint Fit-Up (Excessive* Poor Joint Fit-Up (Excessive * Reduce Root Openings or Gaps* Reduce Root Openings or Gaps
GapGap
* Improper Travel Angle* Improper Travel Angle * Use a Push Angle* Use a Push Angle
* Travel Speed Too Low* Travel Speed Too Low * Increase Travel Speed or Speed* Increase Travel Speed or Speed
of Positionerof Positioner
* Improper Shielding Gas* Improper Shielding Gas * Use a Lower Percentage of CO2* Use a Lower Percentage of CO2
in Shielding Gas (Use Argon Mix)in Shielding Gas (Use Argon Mix)
* Improper Mode of Metal Transfer* Improper Mode of Metal Transfer * Use Short Circuit Mode of Metal* Use Short Circuit Mode of Metal
TransferTransfer
* Insufficient Electrical Stickout* Insufficient Electrical Stickout * Increase Contact Tip to Work * Increase Contact Tip to Work
Piece DistancePiece Distance
BurnthroughBurnthrough
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Insufficient Amperage * Insufficient Amperage *Increase Amperage (WFS)*Increase Amperage (WFS)
* Improper Travel Angle* Improper Travel Angle * Use Less of a Drag Angle* Use Less of a Drag Angle
* Excessive Electrical Stickout* Excessive Electrical Stickout * Decrease Contact Tip to Work* Decrease Contact Tip to Work
Piece DistancePiece Distance
* Improper Shielding Gas * Improper Shielding Gas * Use a Shielding Gas With a* Use a Shielding Gas With a
Higher Percentage of CO2Higher Percentage of CO2
* Improper Wire Selection* Improper Wire Selection * Choose the Correct Wire/Consult* Choose the Correct Wire/Consult
the Manufacturer if Necessarythe Manufacturer if Necessary
* Improper Mode of Metal Transfer* Improper Mode of Metal Transfer * Use Spray Arc or Pulse Spray* Use Spray Arc or Pulse Spray
Arc Mode of Metal TransferArc Mode of Metal Transfer
* Weld Joint Too Narrow* Weld Joint Too Narrow * Increase the Opening of the Weld* Increase the Opening of the Weld
JointJoint
Incomplete PenetrationIncomplete Penetration
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Excessive Amperage* Excessive Amperage * Decrease Amperage (WFS)* Decrease Amperage (WFS)
* Uneven Heating of Work Piece* Uneven Heating of Work Piece * Distribute Heat Evenly Over * Distribute Heat Evenly Over Both Both Pieces of Metal Being Welded Pieces of Metal Being Welded
* Improper Welding Procedures* Improper Welding Procedures * Consult Manufacturer’s* Consult Manufacturer’s
Recommendations Recommendations
* Improper Mode of Metal Transfer* Improper Mode of Metal Transfer * Use Short Circuit Mode of Metal* Use Short Circuit Mode of Metal
TransferTransfer
DistortionDistortion
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Excessive Welding Voltage* Excessive Welding Voltage * Reduce Voltage* Reduce Voltage
* Insufficient Inductance/Slope* Insufficient Inductance/Slope* Increase Inductance (Add Droop)* Increase Inductance (Add Droop)
* Insufficient Electrical Stickout* Insufficient Electrical Stickout * Increase Contact Tip to Work* Increase Contact Tip to Work
* Improper Shielding Gas* Improper Shielding Gas * Use a Higher Percentage of * Use a Higher Percentage of
Argon in the Shielding GasArgon in the Shielding Gas
* Excessive Gas Flow Rate* Excessive Gas Flow Rate * Reduce Gas Flow Rate* Reduce Gas Flow Rate
* Contaminants on Base Material* Contaminants on Base Material * Clean the Work Piece Prior to* Clean the Work Piece Prior to
WeldingWelding
* Contact Tip Recessed Too Much* Contact Tip Recessed Too Much * Use Longer Contact Tip, Shorter* Use Longer Contact Tip, Shorter
Nozzle, or Adjustable NozzleNozzle, or Adjustable Nozzle
Excessive SpatterExcessive Spatter
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Inadequate Gas Coverage* Inadequate Gas Coverage * Increase Flow Rate if Too Low* Increase Flow Rate if Too Low
* Decrease Flow Rate if Weld * Decrease Flow Rate if Weld
Turbulence OccursTurbulence Occurs
* Eliminate Drafts that Can Disrupt* Eliminate Drafts that Can Disrupt
the Shielding Gas Coveragethe Shielding Gas Coverage
* Ensure that Hoses are in Good* Ensure that Hoses are in Good
Repair & Connections are tightRepair & Connections are tight
* Excessive Electrical Stickout* Excessive Electrical Stickout * Decrease Contact Tip to Work* Decrease Contact Tip to Work
Piece DistancePiece Distance
* Contaminants on Base Material* Contaminants on Base Material * Use a Higher Deoxidizing Wire and/or* Use a Higher Deoxidizing Wire and/or
Clean Base MaterialClean Base Material
* Contaminated Shielding Gas or * Contaminated Shielding Gas or * Eliminate Leaks in Gas Lines* Eliminate Leaks in Gas Lines
ElectrodeElectrode * Store and Handle Electrodes* Store and Handle Electrodes
ProperlyProperly
PorosityPorosity
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Insufficient Welding Voltage* Insufficient Welding Voltage * Increase Voltage* Increase Voltage
* Excessive Amperage * Excessive Amperage * Reduce Amperage (WFS)* Reduce Amperage (WFS)
* Excessive Travel Speed* Excessive Travel Speed * Reduce Travel Speed or Speed* Reduce Travel Speed or Speed
of Positionerof Positioner
* Improper Gun Angle* Improper Gun Angle * Reduce Drag Angle* Reduce Drag Angle
* Excessive Electrical Stickout* Excessive Electrical Stickout * Decrease Contact Tip to Work * Decrease Contact Tip to Work
Piece DistancePiece Distance
* Improper Polarity* Improper Polarity * Ensure DC+ Polarity* Ensure DC+ Polarity
* Improper Shielding Gas* Improper Shielding Gas * Use a Higher Percentage of * Use a Higher Percentage of
Argon in the Shielding GasArgon in the Shielding Gas
* Insufficient Inductance* Insufficient Inductance * Increase Inductance Control* Increase Inductance Control
Convex Weld BeadConvex Weld Bead
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Excessive Welding Voltage* Excessive Welding Voltage * Reduce Voltage* Reduce Voltage
* Insufficient Amperage* Insufficient Amperage * Increase Amperage (WFS)* Increase Amperage (WFS)
* Excessive Travel Speed* Excessive Travel Speed * Decrease Travel Speed or Speed* Decrease Travel Speed or Speed
of Positionerof Positioner
* Improper Gun Angle* Improper Gun Angle * Increase Drag Angle* Increase Drag Angle
* Poor Electrode Manipulation* Poor Electrode Manipulation * Improve Technique/Hold the * Improve Technique/Hold the
Corners in Out-of-Position Corners in Out-of-Position Welding Welding
Concave Weld Bead / UndercutConcave Weld Bead / Undercut
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Excessive Amperage* Excessive Amperage * Reduce Amperage (WFS)* Reduce Amperage (WFS)
* Excessive Welding Voltage* Excessive Welding Voltage * Reduce Voltage* Reduce Voltage
* Improper Gun Angle* Improper Gun Angle * Increase Drag Angle* Increase Drag Angle
* Excessive Travel Speed* Excessive Travel Speed * Reduce Travel Speed or * Reduce Travel Speed or SpeedSpeed
of Positionerof Positioner
* Improper Joint Design* Improper Joint Design * Increase Corner Joint Angle* Increase Corner Joint Angle
Arc BlowArc Blow
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Copyright Copyright 2004 Lincoln Global Inc. 2004 Lincoln Global Inc.
Possible CausesPossible Causes Corrective ActionsCorrective Actions* Improper Technique in Crater* Improper Technique in Crater * Increase Crater Fill Time* Increase Crater Fill Time
* Reduce WFS During Crater Fill* Reduce WFS During Crater Fill
* Insufficient Weld Bead Size* Insufficient Weld Bead Size * Decrease Travel Speed* Decrease Travel Speed
Concave Weld(Restraint Crack)Concave Weld(Restraint Crack) * Decrease Travel Angle* Decrease Travel Angle
* “Tramp” Elements in Base * “Tramp” Elements in Base * Reduce Amperage (WFS)* Reduce Amperage (WFS)
MaterialMaterial
* Insufficient Preheat in Certain* Insufficient Preheat in Certain * Increase Preheat Time and/or* Increase Preheat Time and/or
Base Materials (i.e. High Carbon) Base Materials (i.e. High Carbon) Temperature Temperature
* Cooling Rate of Weld Too Fast* Cooling Rate of Weld Too Fast * Insulate/Slow Cool Weld* Insulate/Slow Cool Weld
* Excessive Contaminants on Base* Excessive Contaminants on Base * Clean Work Piece Prior to * Clean Work Piece Prior to
MaterialMaterial Welding Welding
Solidification CrackingSolidification Cracking