Welding takes time and skill to perfect. Having the perfect join every time will require years of experience working with various metals. However, if you notice that you seem to be coming across the same issue every time, perhaps we can help. We explore some of the more common problems found in welds and how you can adapt to prevent them.
1. Splatter
When welding a sheet of metal or join, do you notice little balls of molten metal cooling upon your work piece that regularly need taking off? This is what we would call splatter, and it only happens during the MIG welding process. They can appear on the workpiece and the welding nozzle and cause poor quality welds and regular cleaning of your welder. It also wastes material, which can cost you in the long run.
How to Fix It
Start by checking the settings on your equipment and adjusting them to ensure that you get the optimum settings for your workpiece and fuel. Another part to check is the welding equipment. If you have poor-quality equipment, it will produce poor-quality welds. Finally, you need to check the gas. Using the incorrect gas will also cause problems. Make sure you are using the correct MIG welding gas for your material. Keeping your nozzle clean can also help reduce any splatter.
2. Porosity
Porosity in a weld can be caused by moisture, rust, grease, or paint on the plate edges. So, you get the job done, and it looks great. However, upon closer inspection, there are small holes throughout your joint. This is where small gas bubbles have been trapped in the molten metal. It is a common problem, but it can ruin the overall finish of the weld, risking your reputation and customer confidence. Another issue could be the shielding gas itself.
How to Fix It
There are many reasons for porosity in a weld, but like with most issues, you should always use the correct instruments and equipment. Incorrect welding electrodes, contaminated materials, and poor technique will affect porosity. You should see fewer issues with small holes in your work by correcting these issues. Alternatively, by re-baking, using fres welding consumables and ensuring the material is free from dust or contaminants will offer you better results.
3. Poor Penetration and Fusion
Incomplete root fusion is when the weld fails to fuse one side of the joint in the root. Incomplete root penetration occurs when both sides’ root regions of the joint are unfused, resulting in an excessively thick root face in the weld and many other imperfections.
How to fix It
There are many ways to improve poor penetration issues, including controlling the weld angle, reducing the current of the weld, slowing the welding speed down and reducing the width of the weave. If these don’t improve your fusion, consider changing your posture and checking your equipment for faults.
4. Erratic Arcs
If you have a welding arc that struggles to keep stable through penetrating the workpiece, then an issue is afoot. It will lead to various imperfections, creating uneven welds and poor finishes of your work. It can also make many of the above defects with more splatter potential, and the risk of porosity, which we have established, could cause the join to break easily.
How to Fix It
The first issue to check is the gas supply. A common cause of an erratic arc is the incorrect gas mixture. Whether you are using MIG or TIG welding gas, it could be contributing to an unsteady welding pool. Ensure the consistency is correct; if so, you could check the equipment’s voltage. It could be as simple as needing a minor adjustment. However, if your consistency is correct and your voltage is accurate, it may be time to assess each element to ensure you are using the proper equipment.
5. Brittle Welds
Brittle welds are frequently identified after testing by a visible granular fracture surface, with little or no stretching or yielding. Brittle welds usually incur a resistant spot which can reflect poor performance in the hold of the weld. Depending on the application, it will cost you time and be potentially dangerous.
How to Fix It
To produce high-quality welds which will not break or cause an issue with the workpiece, you should look at the electrodes you are using. A bare or incorrect-sized electrode will most likely result in a brittle join. To increase your chances of producing strong welds, use shielded arc electrodes, avoid using too much current and go over the weld multiple times for confidence and security.
Get the Perfect Weld Every Time
Although there is no hard and fast rule for welding, each job is different in its own way. Following specific procedures can help prevent many common issues from welding.
Keep It Clean
The most important way to ensure the perfection of your weld is to keep all your equipment clean after each job. Wait for the equipment to cool down and remove any excess material, which not only helps to reduce issues but can prolong the life of your equipment. This will save you money in the long run.
Use the Right Equipment for the Right Job
This may take a little more experience, but using the wrong wire feed, gas, or other consumables will guarantee the production of imperfect welds—research which equipment you will need for your specific metal and choose the corresponding welding gas.
Don’t Cut Cost Corners
Make sure you source everything from reputable suppliers. Whilst it may feel cost-effective to find the cheapest consumables available, it may not benefit you in the long run. Poor-quality materials will produce poor-quality work.
As a bottle gas supplier, we take pride in the strict testing of our gas to ensure our customers only receive the best. So if you need to find a high-quality supplier for your welding gas, we are happy to help. You can order our gases online or contact us for a more customised arrangement.