OM-278174 Page 69
10-11. Troubleshooting – Lack Of Penetration
Lack Of Penetration - shallow fusion between weld metal and base metal.
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.
Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power
source.
10-12. Troubleshooting – Incomplete Fusion
Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Possible Causes Corrective Actions
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
10-13. Troubleshooting – Burn-Through
Burn-Through - weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes Corrective Actions
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
10-14. Troubleshooting – Waviness Of Bead
Waviness Of Bead - weld metal that is not parallel and does not cover joint formed by base
metal.
Possible Causes Corrective Actions
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Unsteady hand. Support hand on solid surface or use two hands.
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