Q&A topic

Troubleshooting: 31 questions answered

• Why does my weld have porosity?

  Porosity is caused by gas shield interrupted — wind, empty bottle, loose fittings, or dirty/oily steel. The fix: check gas first: …

• Why does my weld have excessive spatter?

  Excessive spatter is caused by too high current for the wire, too long stick-out, or wrong polarity on gasless wire. The fix: drop…

• Why does my weld have undercut?

  Undercut is caused by too much heat or too fast travel at the weld toe — the parent metal gets washed away. The fix: reduce curren…

• Why does my weld have lack of fusion?

  Lack of fusion is caused by too cold, too fast, or welding over mill scale without penetration. The fix: raise amps, slow travel, …

• Why does my weld have distortion / warping?

  Distortion / warping is caused by uneven heat input across the joint. The fix: tack in sequence, backstep weld, clamp to a strongb…

• Why does my weld have cracking?

  Cracking is caused by high restraint, hydrogen from damp consumables, or fast cooling on thick sections. The fix: preheat, dry rod…

• Why does my weld have blow-through / burn-through?

  Blow-through / burn-through is caused by too much current or too slow travel on thin sheet. The fix: drop amps, move faster, use s…

• Why does my weld have wormtracks (flux-core)?

  Wormtracks (flux-core) is caused by moisture in the wire or slag trapped by too-slow cooling. The fix: store wire dry, raise volta…

• Why does my weld have tungsten contamination?

  Tungsten contamination is caused by dipping the electrode in the pool or touching filler to the tip. The fix: regrind the tungsten…

• Why does my weld have sugaring (stainless)?

  Sugaring (stainless) is caused by back side of the stainless weld oxidising from no shielding. The fix: purge the back of the join…

• Why is my mig welding porosity?

  Porosity in mig welding usually means gas shield interrupted — wind, empty bottle, loose fittings, or dirty/oily steel. For this p…

• Why is my mig welding excessive spatter?

  Excessive spatter in mig welding usually means too high current for the wire, too long stick-out, or wrong polarity on gasless wir…

• Why is my mig welding undercut?

  Undercut in mig welding usually means too much heat or too fast travel at the weld toe — the parent metal gets washed away. For th…

• Why is my mig welding lack of fusion?

  Lack of fusion in mig welding usually means too cold, too fast, or welding over mill scale without penetration. For this process, …

• Why is my mig welding blow-through / burn-through?

  Blow-through / burn-through in mig welding usually means too much current or too slow travel on thin sheet. For this process, drop…

• Why is my mig welding distortion / warping?

  Distortion / warping in mig welding usually means uneven heat input across the joint. For this process, tack sequence and backstep…

• Why is my tig welding porosity?

  Porosity in tig welding usually means gas shield interrupted — wind, empty bottle, loose fittings, or dirty/oily steel. For this p…

• Why is my tig welding tungsten contamination?

  Tungsten contamination in tig welding usually means dipping the electrode in the pool or touching filler to the tip. For this proc…

• Why is my tig welding sugaring?

  Sugaring (stainless) in tig welding usually means back side of the stainless weld oxidising from no shielding. For this process, b…

• Why is my tig welding undercut?

  Undercut in tig welding usually means too much heat or too fast travel at the weld toe — the parent metal gets washed away. For th…

• Why is my tig welding cracking?

  Cracking in tig welding usually means high restraint, hydrogen from damp consumables, or fast cooling on thick sections. For this …

• Why is my tig welding lack of fusion?

  Lack of fusion in tig welding usually means too cold, too fast, or welding over mill scale without penetration. For this process, …

• Why is my stick welding porosity?

  Porosity in stick welding usually means gas shield interrupted — wind, empty bottle, loose fittings, or dirty/oily steel. For this…

• Why is my stick welding excessive spatter?

  Excessive spatter in stick welding usually means too high current for the wire, too long stick-out, or wrong polarity on gasless w…

• Why is my stick welding undercut?

  Undercut in stick welding usually means too much heat or too fast travel at the weld toe — the parent metal gets washed away. For …

• Why is my stick welding cracking?

  Cracking in stick welding usually means high restraint, hydrogen from damp consumables, or fast cooling on thick sections. For thi…

• Why is my stick welding lack of fusion?

  Lack of fusion in stick welding usually means too cold, too fast, or welding over mill scale without penetration. For this process…

• Why is my flux-core welding porosity?

  Porosity in flux-core welding usually means gas shield interrupted — wind, empty bottle, loose fittings, or dirty/oily steel. For …

• Why is my flux-core welding wormtracks?

  Wormtracks (flux-core) in flux-core welding usually means moisture in the wire or slag trapped by too-slow cooling. For this proce…

• Why is my flux-core welding excessive spatter?

  Excessive spatter in flux-core welding usually means too high current for the wire, too long stick-out, or wrong polarity on gasle…

• Why is my flux-core welding lack of fusion?

  Lack of fusion in flux-core welding usually means too cold, too fast, or welding over mill scale without penetration. For this pro…