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Cause: Turbulence caused by too high a rate of shielding gas flow rate
Remedy: Reduce shielding gas flow rate, recommended:
shielding gas flow rate (l/min) = wire diameter (mm) x 10
(e.g. 16 l/min for 1.6 mm wire electrode)
Cause: Too large a distance between the torch and the workpiece.
Remedy: Reduce the distance between the torch and the workpiece(recommended: 10-15 mm)
Cause: Tilt angle of the welding torch is too great
Remedy: Reduce the tilt angle of the welding torch
Cause: Wirefeed components have incorrect diameter
Remedy: Use wirefeed components with correct diameter
Poor wirefeed
Cause: The braking force has been set too high
Remedy: Reduce the braking force
Cause: Hole in the contact tube is displaced
Remedy: Replace the contact tube
Cause: Faulty inner liner in welding torch
Remedy: Check the inner liner for kinks, dirt, etc.
Cause: The wirefeed rollers are not suitable for the wire electrode being used
Remedy: Use suitable wirefeed rollers
Cause: Wirefeed rollers have the wrong contact pressure
Remedy: Optimise the contact pressure
Cause: The wirefeed rollers are soiled or damaged
Remedy: Clean the wirefeed rollers or exchange them for new ones
Cause: Inner liner wrongly laid or kinked
Remedy: Replace inner liner
Cause: Inner liner or wire inlet nozzle wrongly dimensioned
Remedy: Ensure inner liner or wire inlet nozzle are correctly dimensioned
Cause: Inner liner was kinked while being inserted
Remedy: When inserting the inner liner, only handle it around the infeed tube
Cause: The inner liner has been cut too short
Remedy: Replace the inner liner and cut it to the correct length
Cause: After being cut to length, the inner liner is too short
Remedy: Exchange the inner liner and shorten it to the correct length
Cause: Wire electrode worn due to excessive contact pressure at the wirefeed rollers
Remedy: Reduce the contact pressure on the wirefeed rollers
Cause: Wire electrode contains impurities/corroded
Remedy: Use high-quality wire electrode with no impurities
The welding torch becomes very hot
Cause: The welding torch has been operated beyond its maximum number of amps
Remedy: Reduce welding power or use a higher capacity torch
Cause: The design dimensions of the welding torch are not sufficient for this task
Remedy: Observe the duty cycle and loading limits
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