GMAW Troubleshooting Guide

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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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


* 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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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


BurnthroughBurnthrough

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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



* 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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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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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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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



* 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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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


* 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


* 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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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


* 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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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


* Improper Joint Design* Improper Joint Design * Increase Corner Joint Angle* Increase Corner Joint Angle

Arc BlowArc Blow

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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

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