Fronius TPS 3200 MV - Overlap; Weld Bead Rollover; Slag Inclusions; Excessive Spatter; Porosity

13 SEP 12
/ Battery Charging Systems / Welding Technology / Solar Electronics
Overlap / Weld Bead Rollover
Overlap / Weld Bead RolloverOverlap / Weld Bead Rollover
Overlap / Weld Bead Rollover
Weld metal cold and lapped at toe or root
Possible Cause(s⁄
Possible Cause(s⁄Possible Cause(s⁄
Possible Cause(s⁄
 Amperage too high
 Travel speed too slow
 Electrode too large
Porosity
PorosityPorosity
Porosity
Pinholes
Possible Cause(s⁄
Possible Cause(s⁄Possible Cause(s⁄
Possible Cause(s⁄
 Dirty, painted, or galvanized base metal
 Arc length too long
 Moisture in weld
 Insufficient shielding gas coverage
Slag Inclusions
Slag InclusionsSlag Inclusions
Slag Inclusions
Slag trapped in weld
Possible Cause(s⁄
Possible Cause(s⁄Possible Cause(s⁄
Possible Cause(s⁄
 Improper manipulation of covered electrode
 Improper cleaning and/or slag removal between
passes
Cracking
CrackingCracking
Cracking
Cracks in the weld and/or base metal
Possible Cause(s⁄
Possible Cause(s⁄Possible Cause(s⁄
Possible Cause(s⁄
 Using the wrong electrode
 Using excessively high amperage
 Underfill or improper crater geometry (crater
cracking⁄
 Moisture in low hydrogen processes
Excessive Spatter
Excessive SpatterExcessive Spatter
Excessive Spatter
Possible Cause(s⁄
Possible Cause(s⁄Possible Cause(s⁄
Possible Cause(s⁄
 Amperage too high
 Electrode angle too extreme
 Arc length too short/long
 Process driven
Weld Process
Discontinuity
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