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103 Queens Drive | King of Prussia, PA

            ISO 9001:2015 Certified

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.