MIG welding is a common welding technique that uses a wire feeder to continuously feed wire into the weld while an electric arc melts the wire, creating a weld. However, like any welding process, MIG welding can encounter problems and require troubleshooting. Below are some common MIG welding issues and MIG troubleshooting guide! Let’s find out with weldfaq!
MIG Troubleshooting Guide from
1. Lack of penetration
Lack of penetration is a common issue in MIG welding and can be caused by a number of factors. Amperage or low voltage setting, you need to increase the voltage or amperage which can improve penetration.
Another problem is that the wire feed speed is slow, increasing the wire feed speed can improve penetration. Furthermore, using a wire size that is too small for the thickness of the material can lead to a lack of penetration. Be sure to use the proper wire size for the material being soldered.
Improper joint preparation is also a problem of MIG welding. Joints must be cleaned of any contaminants, such as oil or rust, and must be properly aligned to ensure good penetration.
Another problem is that the shielding gas is not suitable. Incorrect shielding gas type or flow rate can result in poor penetration. Be sure to use the correct shielding gas type and flow rate for the material and welding conditions. In addition, you need to adjust the welding technique to suit the weld and the welding material.
Porosity, or small holes or bubbles in the weld, is a common issue in MIG welding and can be caused by a number of factors. Contaminants in the weld area: you should clean the weld area thoroughly before welding to remove any contaminants such as oil, grease, rust, or paint.
Moisture in the shielding gas can cause porosity in the weld. Make sure the shielding gas is dry and stored in a dry location.
Another problem that causes Porosity is Inadequate shielding gas coverage. The shielding gas should completely surround the weld area to protect the weld from the atmosphere. Make sure the shielding gas is flowing properly and is directed at the weld area.
Furthermore, using a wire size that is too small for the thickness of the material can result in porosity. Make sure to use the appropriate wire size for the material being welded. Some wire chemistries are more susceptible to porosity than others, it’s important to use the correct wire chemistry for the specific process and material.
Another problem that causes this phenomenon when you MIG welding is the Incorrect welding technique. Improper welding technique can cause porosity in the weld. The welder should be properly trained and have enough experience on the specific process.
Burn-through is a common issue in MIG welding and can be caused by a number of factors. The problem could be due to high amperage or voltage settings. So you need to reduce the voltage or amperage that can prevent burning through.
You can create unsatisfactory welds with the wrong wire size. Using a wire size that is too large for the thickness of the material may lead to wire burn. Be sure to use the proper wire size for the material being soldered.
Improper joint preparation is also a matter of concern. Joints must be cleaned of any contaminants, such as oil or rust, and must be properly aligned to ensure good penetration.
Furthermore, too small a gap can lead to burn-through. Make sure there is an appropriate distance between the work pieces. You also need to make sure to use the correct shielding gas type and flow rate for the material and welding conditions.
Spatter is a common problem when using a MIG welding process. It is caused by small droplets of molten metal that are expelled from the weld and solidify before they can be completely incorporated into the weld. This can create a rough, uneven surface on the finished weld and can also cause porosity, or small holes, in the weld.
Inappropriate wire feed speed can also be the cause of this phenomenon. If the wire feed speed is too fast, it may cause splashing. Reducing the wire feed speed will help reduce splashing.
In addition, air flow that is too low or too high can cause splashes. The correct gas flow rate must be specified in the manual of the welding equipment.
Incorrect gun angle or dirty or worn gun liner are also problems. Holding the gun at the wrong angle can cause shooting, the gun must be held at a 90 degree angle to the workpiece. Dirty or worn gun liner can cause splashing, liner should be cleaned or replaced to reduce splash.
The workpiece is dirty or contaminated. Dirty or contaminated workpieces can cause splashing. Workpieces must be clean and free of oil, rust or other contaminants prior to welding.
In addition, incorrect contact tip size can cause splashes. Exact dimensions must be specified in the manual of the welding equipment.
It is also important to note that some spatter is normal during MIG welding, but excessive sparks can indicate a problem that needs to be addressed.
Rounding It Up
Above is the common problems and MIG troubleshooting guide. It is important to consult the operator manual for the specific machine you are using, as the troubleshooting process can vary between different types of MIG welding machines. It is also important to note that in case of any doubt or uncertainty, it is always recommended to contact the manufacturer or a welding professional.