Common MIG Welding Errors and MIG Troubleshooting Guide

MIG welding has its unique challenges, just like any other welding procedure. For untrained persons, it can be very challenging to have a flawless weld free of porosity or mistake. So what should you do if your MIG welding machine develops a basic error? Rest assured, weldfaq has provided the MIG troubleshooting guide right below for you.

Common Problems and MIG Troubleshooting Guide

The machine fails to start

Reason: There are a variety of reasons why the MIG welder won’t turn on. Dead circuits, explosions, or simply starting at the incorrect voltage are a few common causes. It might also come via a download.

Solution: Check to see if your computer is turned on first if it won’t boot. If so, investigate the issue’s potential root cause and fix it. To avoid overloading and to make sure the voltage input complies with the guidelines, it should be examined. It is advisable to let the gadget minimize the time if it is overwhelmed. In case the request explodes, you can easily replace it.

Irregular arc

Reason: If your arc flashes or crackles, there may be a conductivity or wiring issue at play.

Solution: First, check to see if your drive tray is free of dust or other debris. Make sure your drive roll tension is enough after that. Check your liner’s interior; there shouldn’t be any debris there. If so, modify it. Additionally, remember to replace your solder tips frequently because deteriorated tips can interfere with conductivity and degrade the quality of your weld.

Common Problems and MIG Troubleshooting Guide

The phenomenon of pitting occurs

Reason: Pitting happens when an air pocket gets wedged inside the metal used for the weld. This discontinuity may show up anywhere along the weld, along its whole length, on the weld’s surface, or even inside it. One of the most frequent reasons of air porosity is a lack of suitable protective gas covering.

Solution: Make sure there is enough airflow by checking the regulator or flow meter; if not, increase it; and look for leaks in the air duct and cannon as well. Use a welding shield to protect the arc and weld pool from drafts whether you’re welding inside or outside. Next, make sure the MIG gun’s nozzle is the appropriate size for the application; otherwise, shielding gas may not flow as well.

Porosity in welding

Reason: Gas that becomes trapped in the weld metal causes porosity. One of the main causes is insufficient shielding gas coverage. Porosity in the weld can be brought on by excessive air flow. Pitting in your welds might also be brought by by insufficient gas coverage.

Solution: For proper airflow, check the regulator or flow meter, and adjust as necessary. If you find any leaks, check the air ducts and the welding gun, and then shut off the welding area. It is advised to utilize a nozzle that is sufficiently large to completely cover the welding puddle with gas while maintaining a clean, splash-free nozzle.

Excessive penetration

Reason: When the weld metal pours through the base metal and hangs below the weld, excessive fusion takes place. The issue is frequently caused by an excessive heat intake.

Solution: Select a lower voltage range, slow down the wire feed, and quicken your travel. On the other hand, a lack of heat can result in under-melting or shallow melting between the base metal and the weld metal. Remedy options include increasing wire feed rates, increasing voltage ranges.

Common Problems and MIG Troubleshooting Guide

Concave and convex weld bead

Reason: Gravity resistance is the only cause of concave weld beads, which are particularly prevalent when welding vertical applications. The most common causes of concave welds that appear flat or horizontally are excessive voltage, slow wire feed rates, and quick travel speeds.

Solution: Reduce the setting of the parameters to make the weld puddle less liquid and more likely to fill the joint. Or, to avoid convex particles, raise the voltage. Always adhere to the suggested welding techniques, use the right shielding gas for the material, and polarize the wire according to the instructions.

The phenomenon of penetrating fire

Reason: Penetration happens when the weld metal completely penetrates the base material. This is particularly common when welding thin materials smaller than 1/8 inch thick, or around 12 yards. The fundamental cause of fire is too much heat.

Solution: Reduce the speed or voltage of the wire feed. Increasing travel speed can be useful as well, especially when MIG welding thin aluminum or other materials that are particularly prone to heat buildup.

The phenomenon of penetrating fire

Frequently asked questions (Weld FAQ)

What to do when the MIG welder does not produce wires?

A common error when using a MIG welder is that it sometimes pulls the trigger, sometimes it doesn’t output a wire, and sometimes it does. In such a case, inspect the control switch for any damage. If so, kindly fix or change.

What does a deformed weld look like?

When a metal cannot withstand the expansion and contraction brought on by heating and cooling, deformation, also known as warping, occurs. The metal frequently appears to be pulling and warping. This indicates that there is frequently too much heat in the plate, which the metal cannot tolerate as well as the joint.

What are the problems of MIG welding?

The most common welding errors that you may encounter when welding are: porosity, cracks, clipping, burning, convex and concave solder beads,… In addition, you may experience some other error cases.

Wrapping up

It is totally typical for the MIG welding machine to malfunction for unskilled welders. When you go through such periods, your welds get better and better in appearance. Above is an article about MIG Troubleshooting Guide. The information in the aforementioned article should assist those who are new to MIG welding procedures in understanding the reasons for faults and how to correct them to increase work productivity.

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