Welding Issues & Possible Solutions
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Contact tip burn back. | 1 | Improper voltage and/or wire feed speed. | 1 | Set parameters. |
| Extended Solutions for Contact tip burn back | 2 | Erratic wire feeding. | 2 | See ‘Erratic Wire Feeding’. |
| 3 | Improper tip stickout. | 3 | Adjust nozzle / tip relationship. | |
| 4 | Improper electrode stickout. | 4 | Adjust torch to base metal relationship. | |
| 5 | Faulty ground. | 5 | Repair all cables & connectors. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Short contact tip life. | 1 | Improper voltage and/or wire feed speed. | 1 | Set parameters. |
| Extended Solutions for Short contact tip life | 2 | Erratic wire feeding. | 2 | See ‘Erratic Wire Feeding’. |
| 3 | Improper tip stickout. | 3 | Adjust nozzle / tip relationship. | |
| 4 | Improper electrode stickouot. | 4 | Adjust torch to base metal relationship. | |
| 5 | Faulty ground. | 5 | Repair all cables & connections. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Erratic arc. | 1 | Worn contact tip. | 1 | Replace contact tip. |
| Extended Solutions for Erratic arc | 2 | Buildup inside of liner. | 2 | Replace liner, check condition of electrode. |
| 3 | Wrong tip size. | 3 | Replace with correct tip size. | |
| 4 | Not enough bend in gooseneck. | 4 | Replace with 45° or 60° gooseneck. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Electrode does not feed or erratic wire feeding. | 1 | Feeder relay / malfunction. | 1 | Consult feeder manufacturer. |
| 2 | Broken control lead. | 2 | a. Test & connect spare control lead. | |
| b. Install new cable. | ||||
| Extended Solutions for Wire does not feed | 3 | Poor adaptor connection. | 3 | Test & replace leads and/or contact pins. |
| 4 | Worn or broken switch. | 4 | Replace switch. | |
| 5 | Improper drive roll size. | 5 | Replace with proper size. | |
| 6 | Drive roll tension misadjusted. | 6 | Adjust tension at feeder. | |
| Extended Solutions for Erratic wire feeding | 7 | Burn back to contact tip. | 7 | See ‘Contact Tip Burn Back’. |
| 8 | Wrong size liner. | 8 | Replace with correct size. | |
| 9 | Buildup inside of liner. | 9 | Replace liner, check condition of electrode. | |
| 10 | Worn drive roll. | 10 | a. Replace with new drive roll. | |
| b. Stone edge of groove on drive roll. | ||||
| 11 | Improper guide tube relationship. | 11 | a. Adjust/replace guide as close to drive rolls as possible. | |
| b. Eliminate all gaps in electrode path. | ||||
| 12 | Improper wire guide diameter. | 12 | Replace with proper guide diameter. | |
| 13 | Gaps at liner junctions. | 13 | Replace with new liner – be sure to measure accurately before cutting. | |
| 14 | Contact tip. | 14 | Inspect & replace. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Extreme Spatter. | 1 | Improper machine parameters. | 1 | Adjust parameters. |
| Extended Solutions for Extreme Spatter | 2 | Improper tip installation. | 2 | Adjust nozzle / tip relationship. |
| 3 | Improper shielding. | 3 | a. Verify shielding gas coverage. | |
| b. Verify gas mixture. | ||||
| 4 | Contaminated wire or work piece. | 4 | Clean wire and work piece. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Porosity in weld. | 1 | Insulator worn. | 1 | Replace nozzle / insulator. |
| Extended Solutions for Porosity in weld | 2 | Retaining head damaged. | 2 | Replace retaining head / diffuser. |
| 3 | Extreme heat or duty cycle. | 3 | Replace with heavier consumables. | |
| 4 | Solenoid faulty. | 4 | Replace solenoid. | |
| 5 | No gas. | 5 | a. Install full tanks. | |
| b. Check supply. | ||||
| c. Check for hose leaks. | ||||
| 6 | Flow improperly set. | 6 | Adjust. | |
| 7 | Gas ports plugged. | 7 | a. Clean or replace gas diffuser / retaining head. | |
| b. Clean nozzle. | ||||
| 8 | Ruptured gas hose. | 8 | Repair or replace cable or line. | |
| 9 | Control circuit loss. | 9 | See ‘Electrode Does Not Feed’. | |
| 10 | Worn, cut or missing o-rings. | 10 | Replace o-rings. | |
| 11 | Loose fittings. | 11 | Tighten torch & cable connections to specified torque. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Torch running hot. | 1 | Exceeding duty cycle. | 1 | a. Replace with properly rated gun. |
| Extended Soultions for Torch or gun running hot | b. Decrease parameters to within gun rating. | |||
| 2 | Loose or poor power connection. | 2 | a. Clean, tighten or replace cable grounding connection. | |
| b. Tighten gun & cable connections to specified torque. | ||||
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Liner is discolored full length. | 1 | Short circuit to electrode. | 1 | Isolate electrode reel from feeder and drive block. |
| Consult feeder manufacturer’s manual. | ||||
| 2 | Broken copper stranding in power cable. | 2 | Replace gun. | |
| PROBLEM | POSSIBLE CAUSE | POSSIBLE SOLUTION | ||
| Tip disengages from retaining head. | 1 | Worn retaining head / diffuser. | 1 | Replace tip and/or diffuser. |
| 2 | Improper tip installation. | 2 | Install as per your product Spec Sheet or Operations Manual. | |
| 3 | Extreme heat or duty cycle. | 3 | Replace with heavy duty consumables. | |
