OM-923 Page 33
8-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes Corrective Actions
Metal Thickness Selector switch set too
high.
Set Metal Thickness Selector switch to a lower selection.
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.
8-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes Corrective Actions
Wrong gas. Use welding grade shielding gas; change to different gas.
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.
8-10. Troubleshooting − Excessive Penetration
Good Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration
S-0639
Possible Causes Corrective Actions
Excessive heat input. Set Metal Thickness Selector switch to a lower selection.
Increase travel speed.
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