Common Welding Problems and Solutions

Welding is a complex process, and various problems are often encountered during actual operations. Metaco will introduce some common welding problems and provide simple and easy-to-understand solutions.

1. Porosity

Porosity refers to small holes in the weld, which are usually caused by air or gas being trapped in the welding material during the welding process. These pores may affect the strength of the weld.

Solution: Keep the welding rods dry, slightly increase the current, and avoid welding in damp environments.

2. Cracks

Welding cracks are fissures that form during the welding process, typically on the material surface or within the weld. Cracks can weaken the weld strength and even lead to structural failure.

Solution:

Control the temperature: Avoid excessively high temperatures during welding, and reduce the current to control the heat.

Choose suitable materials: Ensure that the welding material and the base material match to avoid cracks.

Slow cooling: Do not let the material cool too quickly after welding, as this could create a large temperature differential that causes cracks.

3. Lack of Fusion

Lack of fusion occurs when the weld does not completely integrate with the material, resulting in a weak connection. This usually happens when the material is too thick.

Solution: Maintain a steady speed: Ensure the welding speed is neither too fast nor too slow to maintain consistency.

4. Burnthrough

Burnthrough occurs when excessive heat causes the material to burn through. This commonly happens when welding thin plates.

Solution:

Reduce the current: High current results in excessive heat, which can lead to burnthrough.

Increase the welding speed: Speeding up the welding process helps prevent heat from concentrating in one area for too long.

Adjust the welding angle: Ensure the welding torch is at the correct angle to avoid uneven welds.

5. Spatter

Spatter refers to molten metal splashing out during the welding process, leaving small particles around the weld. These spatters not only affect the appearance of the weld but also increase the post-welding cleaning workload.

Solution:

Reduce current and voltage: High current and voltage can cause spatter, so adjust accordingly.

Use shielding gas: Shielding gases can help reduce impurities in the air and minimize spatter.