0-5461 5-11 OPERATION
5.20 Welding Problems
Description Possible Cause Remedy
1 Gas pockets or voids in weld metal
(Porosity)
A Electrodes are damp A Dry electrodes before use
B Welding current is too high B Reduce welding current
C Surface impurities such as oil,
grease, paint, etc
C Clean joint before welding
2 Crack occurring in weld metal soon
after solidification commences
A Rigidity of joint A Redesign to relieve weld
joint of severe stresses
or use crack resistance
electrodes
B Insufficient throat thickness B Travel slightly slower to
alloy greater build-up in
throat
C Cooling rate is too high C Preheat plate and cool
slowly
3 A gap is left by failure of the weld
metal to fill the root of the weld
A Welding current is too low A Increase welding current
B Electrode too large for joint B Use smaller diameter
electrode
C Insufficient gap C Allow wider gap
D Incorrect sequence D Use correct build-up
sequence
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