OM-270 231 Page 30
9-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
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Possible Causes Corrective Actions
Wire feed speed too high. Select lower wire feed speed.
Voltage too high. Select lower voltage range.
Electrode extension (stickout) too long. Use shorter electrode extension (stickout).
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
9-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
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Possible Causes Corrective Actions
Dirty welding wire. Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
9-10. Troubleshooting − Excessive Penetration
Good Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration
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Possible Causes Corrective Actions
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase travel speed.
9-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow
fusion between weld metal and
base metal.
Lack of Penetration Good Penetration
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Possible Causes Corrective Actions
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
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