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GMAW Troubleshooting Guide

The document provides troubleshooting guidance for common issues that can occur during gas metal arc welding. It lists possible causes and recommended corrective actions for problems such as wire burnback, inconsistent arc starting, burnthrough, incomplete penetration, distortion, excessive spatter, porosity, convex or concave weld beads, arc blow, and solidification cracking.

Uploaded by

Vijayan Munuswamy
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
376 views

GMAW Troubleshooting Guide

The document provides troubleshooting guidance for common issues that can occur during gas metal arc welding. It lists possible causes and recommended corrective actions for problems such as wire burnback, inconsistent arc starting, burnthrough, incomplete penetration, distortion, excessive spatter, porosity, convex or concave weld beads, arc blow, and solidification cracking.

Uploaded by

Vijayan Munuswamy
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Gas Metal Arc Welding

Weld Troubleshooting Guide


1
Copyright 2004 Lincoln Global Inc.

Wire Burnback
Possible Causes
* Drive Rolls in Poor Condition * Excessive Welding Voltage * Insufficient Electrical Stickout * Contact Tip in Poor Condition * Liner in Poor Condition * Excessive Burn-back Time * Spatter on Contact Tip

Corrective Actions
*Tighten, Clean, or Replace Drive Rolls * Reduce Voltage * Increase Contact Tip to Work Piece Distance * Clean or Replace Contact Tip * Blow Out Liner with Compressed Air or Replace Liner * Reduce Burn-back Time * Remove Spatter at Regular Intervals of Time, Use Anti-Spatter Compounds in Gun

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Copyright 2004 Lincoln Global Inc.

Inconsistent Arc Starting


Possible Causes
* Excessive Run-In Speed * Excessive Welding Amperage * Insufficient Welding Voltage * Excessive Electrical Stickout

Corrective Actions

*Reduce Run-In Speed * Reduce Amperage (WFS) * Increase Voltage * Decrease Contact Tip to Work Piece Distance * Contact Tip in Poor Condition * Clean or Replace Contact Tip * Poor Work Piece Connection * Tighten Work Piece Connection or in Poor Condition or Replace Cables * Excessive Inductance/Insufficient * Decrease Inductance Control Pinch Control * Contaminants on Base Material * Clean Work Piece Prior to Welding

3
Copyright 2004 Lincoln Global Inc.

Burnthrough
Possible Causes
* Excessive Amperage * Poor Joint Fit-Up (Excessive Gap * Improper Travel Angle * Travel Speed Too Low

Corrective Actions
*Reduce Amperage (WFS) * Reduce Root Openings or Gaps

* Use a Push Angle * Increase Travel Speed or Speed of Positioner * Improper Shielding Gas * Use a Lower Percentage of CO2 in Shielding Gas (Use Argon Mix) * Improper Mode of Metal Transfer * Use Short Circuit Mode of Metal Transfer * Insufficient Electrical Stickout * Increase Contact Tip to Work Piece Distance

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Copyright 2004 Lincoln Global Inc.

Incomplete Penetration
Possible Causes
* Insufficient Amperage * Improper Travel Angle * Excessive Electrical Stickout

Corrective Actions

*Increase Amperage (WFS) * Use Less of a Drag Angle * Decrease Contact Tip to Work Piece Distance * Improper Shielding Gas * Use a Shielding Gas With a Higher Percentage of CO2 * Improper Wire Selection * Choose the Correct Wire/Consult the Manufacturer if Necessary * Improper Mode of Metal Transfer * Use Spray Arc or Pulse Spray Arc Mode of Metal Transfer * Weld Joint Too Narrow * Increase the Opening of the Weld Joint

5
Copyright 2004 Lincoln Global Inc.

Distortion
Possible Causes
* Excessive Amperage * Uneven Heating of Work Piece

Corrective Actions

* Decrease Amperage (WFS) * Distribute Heat Evenly Over Both Pieces of Metal Being Welded * Improper Welding Procedures * Consult Manufacturers Recommendations * Improper Mode of Metal Transfer * Use Short Circuit Mode of Metal Transfer

6
Copyright 2004 Lincoln Global Inc.

Excessive Spatter
Possible Causes
* Excessive Welding Voltage * Insufficient Inductance/Slope * Insufficient Electrical Stickout * Improper Shielding Gas

Corrective Actions

* Reduce Voltage * Increase Inductance (Add Droop) * Increase Contact Tip to Work * Use a Higher Percentage of Argon in the Shielding Gas * Excessive Gas Flow Rate * Reduce Gas Flow Rate * Contaminants on Base Material * Clean the Work Piece Prior to Welding * Contact Tip Recessed Too Much * Use Longer Contact Tip, Shorter Nozzle, or Adjustable Nozzle

7
Copyright 2004 Lincoln Global Inc.

Porosity
Possible Causes
* Inadequate Gas Coverage

Corrective Actions
* Increase Flow Rate if Too Low * Decrease Flow Rate if Weld Turbulence Occurs * Eliminate Drafts that Can Disrupt the Shielding Gas Coverage * Ensure that Hoses are in Good Repair & Connections are tight * Decrease Contact Tip to Work Piece Distance * Use a Higher Deoxidizing Wire and/or Clean Base Material * Eliminate Leaks in Gas Lines * Store and Handle Electrodes Properly
Copyright 2004 Lincoln Global Inc.

* Excessive Electrical Stickout


* Contaminants on Base Material * Contaminated Shielding Gas or Electrode
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Convex Weld Bead


Possible Causes
* Insufficient Welding Voltage * Excessive Amperage * Excessive Travel Speed * Improper Gun Angle * Excessive Electrical Stickout

Corrective Actions
* Increase Voltage * Reduce Amperage (WFS) * Reduce Travel Speed or Speed of Positioner * Reduce Drag Angle * Decrease Contact Tip to Work Piece Distance * Ensure DC+ Polarity * Use a Higher Percentage of Argon in the Shielding Gas * Increase Inductance Control

* Improper Polarity * Improper Shielding Gas


* Insufficient Inductance

9
Copyright 2004 Lincoln Global Inc.

Concave Weld Bead / Undercut


Possible Causes
* Excessive Welding Voltage * Insufficient Amperage * Excessive Travel Speed * Improper Gun Angle * Poor Electrode Manipulation

Corrective Actions
* Reduce Voltage * Increase Amperage (WFS) * Decrease Travel Speed or Speed of Positioner * Increase Drag Angle * Improve Technique/Hold the Corners in Out-of-Position Welding

10
Copyright 2004 Lincoln Global Inc.

Arc Blow
Possible Causes
* Excessive Amperage * Excessive Welding Voltage * Improper Gun Angle * Excessive Travel Speed * Improper Joint Design

Corrective Actions
* Reduce Amperage (WFS) * Reduce Voltage * Increase Drag Angle * Reduce Travel Speed or Speed of Positioner * Increase Corner Joint Angle

11
Copyright 2004 Lincoln Global Inc.

Solidification Cracking
Possible Causes
* Improper Technique in Crater * Insufficient Weld Bead Size Concave Weld(Restraint Crack) * Tramp Elements in Base Material * Insufficient Preheat in Certain Base Materials (i.e. High Carbon) * Cooling Rate of Weld Too Fast * Excessive Contaminants on Base Material

Corrective Actions
* Increase Crater Fill Time * Reduce WFS During Crater Fill * Decrease Travel Speed * Decrease Travel Angle * Reduce Amperage (WFS) * Increase Preheat Time and/or Temperature * Insulate/Slow Cool Weld * Clean Work Piece Prior to Welding

12
Copyright 2004 Lincoln Global Inc.

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