OM-272384 Page 25
C. Common Problems/Troubleshooting
l Melt through caused by over heating the base material.
– Increase travel speed. Use sequencing to make shorter welds.
– Sequence welds.
– Use thicker material, change joint design or welding process to AC TIG.
– Eliminate or reduce gaps.
l Dirty welds.
– Use push angle instead of drag technique.
– Increase voltage to get into spray transfer, if unit output is capable of this process.
– Use proper base metal cleaning techniques (stainless steel brush).
– Check for proper shielding gas and wire alloy type.
l Wire burns back to contact tip during or at the end of the weld.
– Maintain a 3/4 in. (19 mm) tip-to-work distance.
– Check to make sure the contact tip size, drive rolls and gun liner match the wire diameter that you are using. (Sometimes an oversized
tip can be used. The ID should only be one size larger than the wire diameter.)
l Wire "bird nests" (piles up) in front of inlet guide on gun.
– Check and adjust drive roll tension.
– Check to make sure drive rolls match wire diameter.
– Replace contact tip if fouled or plugged. (Sometimes an oversized tip can be used. The ID should only be one size larger than the wire
diameter.)
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