Troubleshooting Guide for GMAW Welding

Excessive Spatter

Scattering of molten metal droplets that solidify on the plate near the weld

POSSIBLE CAUSES	CORRECTIVE ACTIONS
Wire feed speed too high	Reduce the wire feed speed.
Inadequate voltage	Use the voltage recommended by the wire manufacturer for the gas and wire speed used.
Electrode free length (stickout) too long	Reduce the electrode free length (stickout).
Welding piece too dirty	Remove all traces of grease, oil, moisture, paint, surface coating, and dust from the welding area.
Insufficient gas shield at the welding arc	Increase the gas flow at the regulator/flowmeter and/or prevent drafts in the welding area.
Welding wire too dirty	– Use clean and dry wire. – Use a lubricating pad to remove oil and lubricant from the feeder or sheath on the wire.

Porosity – Small cavity or hole caused by the entrapment of gas pockets in the weld

POSSIBLE CAUSES	CORRECTIVE ACTIONS
Inadequate gas shielding	– Check if you have a good gas flow. – Clean the gun nozzle. – Check for any leaks in the gas hose or nozzle assembly. – Eliminate drafts in the welding area – Position your welding nozzle 1/4 – 5/8 in from the welding piece. – Keep the gun above the weld until the bead completely solidifies.
Wrong gas	Use the appropriate welding gas for the type of metal being welded.
Welding wire too dirty	– Use clean and dry wire. – Use a lubricating pad to remove oil and lubricant from the feeder or sheath on the wire.
Welding piece too dirty	Remove all traces of grease, oil, moisture, paint, surface coating, and dust from the welding area.
Electrode free length (stickout) too long	Reduce the electrode free length (stickout). Reduce the distance between the nozzle and the piece to less than 5/8 in

The molten pool is unable to merge the base metal or the preceding bead

POSSIBLE CAUSES	CORRECTIVE ACTIONS
Welding piece too dirty	Remove all traces of grease, oil, moisture, paint, surface coating, and dust from the welding area.
Insufficient linear energy	Increase the voltage and/or wire speed.
Poor welding technique	– Make a small straight bead in the targeted area. – Adjust the attack angle or increase the gap of the preparation to facilitate access to the root of the joint. – Temporarily maintain the arc on the joint preparation if you are oscillating in the joint. Keep the welding arc in the region at the beginning of the fusion zone. – Use the correct travel angle. Tilt the nozzle between 0°-15° while pushing in the direction of travel.

The molten pool breaks through the root of the joint and exceeds the underside of the plate

POSSIBLE CAUSES	CORRECTIVE ACTIONS
Too high linear energy	Reduce the voltage and/or wire speed.
Insufficient wire feed speed	Increase the wire feed speed.
Incorrect joint preparation	– Use a different joint preparation. – Make a smaller root opening. – Adjust the electrode free length (stickout).
Incorrect welding technique	– Use the correct travel angle. Tilt the nozzle between 0°-15° while pushing in the direction of travel. – Make a small straight bead in the targeted area. – Adjust the attack angle or increase the gap of the preparation to facilitate access to the root of the joint. – Temporarily maintain the arc on the joint preparation if you are oscillating in the joint. Keep the welding arc in the region at the beginning of the fusion zone.