MIG Welder Troubleshooting Guide

A five-year journey with love and dedication. MIG welder troubleshooting guide provides welding troubles and their explanation.

Welding Defects And Causes

Like another welding process, MIG welding has some complications. However, knowing these complications will protect the machine from problems and their solution. Here I’m going to tell you about some common MIG welder troubleshooting. You can boost the quick fix to your welding defects. 

welding troubleshooting:

Basic Problems

Some basic problems of MIG welder are described as below:

Machine Starting Problem:

Reason:

The machine can create a problem for starting because of many reasons. Some fundamental rights are wrong input voltage, blown up of fuse, or having a problem in the circuit. Further, having the problem of starting the machine can cause overheating.

Key:

If you notice that the machine is not starting, then you have to check first that the machine is properly switched. If it is just changed then check the other possible reason and solve them. You must verify the input voltage is set correctly. And follow the manual for avoiding this problem. Alternately, if the machine gets overheated then shut down it and keep it for cooling down. If the fuse blows up, then you must replace it as early as possible.

Machine Fuse Blows:

Reason:

If you turn on the machine and it starts correctly, and suddenly the fuse creates trouble then there has a defective fuse. It may result in a short circuit. As well, the other reason may be the wick is too small for the machine.

Key:

Noticing this problem, you have to solve the short circuit. Rather, if the fuse is too small for the machine then change the fuse with a bigger fuse to avoid this problem.

Polarity Switch Doesn’t Work:

Reason:

If the polarity switch is worn out or the welder is under load then the polarity switch stops working.

Key:

Noticing this problem, you must change the polarity switch. Aand make sure that you are not using the welder under load conditions.

Electrode Holder’s Excess Heats up:

Reason:

If there has a loose connection or has set an irregular duty cycle then the electrode holder will heat up.

Key:

To solve this problem you must tighten the connection. In preference, if caused by an irregular duty cycle then you have to change that with the proper size.

Electrical Shocks:

Reason:

If you are not grounded in the frame of the welder machine properly then it may cause electrical shocks.

Key:

In this case, you have to follow the manual and instructions. To avoid electric shocks you have to ground the frame perfectly. If you ground the chassis correctly, then you will not face any electrical shocks.

Excess Heat Of Welding Cable:

Reason:

If the cable is in a defective condition or the duty cycle is improper then the wire will heat up very faster.

Key:

For avoiding this problem you must change the cable to the proper condition and size. Yet, you will know the appropriate scope of wire in the user manual.

Ground Clamp Turns Bad:

Reason:

When the machine gets implicated by oxides that can change the flow of current. And can create a high stumbling block for the machine then the ground clamp will be in lousy condition.

Key:

Make sure that you are cleaning the ground clamp regularly. To avoid the building up of oxides that cause the creation of a stumbling block for the machine.

Cable Damage:

Reason:

If you are using the cable for a long time then it can damage.

Key:

If you notice that the cable is in a damaged condition then you must change it instantly. Otherwise, it will affect your working quality and create a problem too.

Welding Faults

If you notice any poor welding result then you may replace or repair the parts of the welder. Due to poor welding result only causes defective portions of the machine. Below are given some common welding defects and its solution.

Inappropriate Wire Feeding:

Reason:

A widespread welding defect may cause by inappropriate MIG welder wire feed problems. That occurred by worn driver rolls.

Key:

Clean the driver roll periodically and remove all the dirt from the liner to avoid this problem. Besides, replace the driver roll if it’s necessary.

Low Welding:

Reason:

When the welding gun’s tip worn out then it can cause flat welding. If it happens suddenly, you won’t get a proper welding result.

Key:

You must replace the tip just after noticing this problem.

Porosity:

Reason:

Another common welding defect is porosity. Insufficient gas flow occurs.

Key:

For avoiding this problem you must check that the gas nozzle rightly plugs in. Again check that the wired connection plugs in properly.

Shrinkage Crash On The Weld:

Reason:

If the wire is pale or having a small follicle can cause a shrinkage crash on the weld.

Key:

If the follicle is of sufficient size then you won’t face this problem. Always remember that there is no rust in the welding area.

Lateral Cracks On The Weld:

Reason:

Lateral cracks on the weld can occur by the fast welding speed or low current or high arc voltage.

Key:

For avoiding Lateral cracks on the weld, maintain a constant welding speed. Make sure that the arc voltage is still constant.

Excess Spatter:

Reason:

Excess spatter is a widespread welding defect. It can be caused by high voltage or excess CO2 or improper impedance.

Key:

By using a gas heater you can avoid this problem. You can along prevent excess spatter by using appropriate voltage.

Advanced Welding Problems

Some advanced problems of mig welder and their solutions are described as below:

1.Weld Metal Absorbency Or Porosity

A.Absorbency or Porosity Problem 

Surface Conditions Inappropriate:

Metal porosity can causes if the surface is contaminated with rust, grease, and oil. Likewise, a surface that is open in the atmospheric air causes metal porosity.

Key:

For avoiding the contaminated surface, clean the material at the following methods.

B.Absorbency Problem  

Gas Coverage:

The inappropriate gas shield can cause a porosity problem. The function of shielding gas is to protect the weld puddle from the air. If the shielding gas change with wind then porosity occurs.

Key:

If the gas hose is attached to the equipment correctly then there is no chance to catch the air and can cause porosity.

C.Absorbency Problem

Mismatch Base Metal:

The mismatched base metal creates another common porosity problem. For example, you are not using the same baking bar material of the metal that you are welding.

Key:

To avoid this problem you have to use the same baking bar material of the metal that you are going to weld.

2.Inappropriate Weld Bead Profile

A.Inappropriate Bead Problem

Heat Inputs Lacking:

Improper input power can be caused by a bead problem.

Key:

For avoiding this problem, set the input power correctly according to the thickness of the metal.

B.Inappropriate Bead Problem 

Incorrect Technique:

Using the wrong technique in welding can cause bead problems.

Key:

For avoiding this problem, you must adopt the right technique of welding.

C.Inappropriate Bead Problem

Insufficient Work Cable:

Using a small cable in welding will cause a bead problem.

Key:

Use the appropriate size of cable to avoid this problem.

3.Fusion Shortage

Fusion Shortage Problem

Cold Lapping:

The lacking of fusion occurs in cold lapping. In this method, the wire straightly touches the welding pool and melts the wire.

Key:

For avoiding cold lapping you must check that the voltage and amperage are in the right form.

4.Defective Wire Delivery

A.Defective Wire Delivery Problem

Contact Tip:

The contact tips can occur faulty wire delivery. The tips can get obstructed by the overplus of spatter or by touching on the welding puddle.

Key:

You can solve this problem by just changing the contact tips. Anyhow, you must remember one thing that you are using the right size of contact tips.

B.Defective Wire Delivery Problem

Gun Liner:

Inappropriate size of the gun liner can cause the short wire delivery. It also creates by extending wire.

Key:

To avoid this problem you have to use the proper size of the gun liner. Including, make sure that you are cleaning the gun liner regularly to keep them free from dust. You have to change the ships frequently.

C.Defective Wire Delivery Problem

Worn Out Gun:

Worn out gun can create wire feeding problem.

Key:

After noticing this problem, you must replace or change the worn-out gun instantly.

D.Defective Wire Delivery Problem

Drive Roll:

Inappropriate drive roll pressure can create a problem in wire feeding. When the drive roll is too loose, then the wire feeding will stop, or if the drive is too tight, then it will crash.

Key:

You must keep the drive roll pressure in such a way that is not too loose or not too tight for avoiding this kind of problem.

MIG Welder Troubleshooting Guide

Outcome

I guess you have got enough knowledge about MIG welding troubleshooting. If you want to avoid the accident by the machine, then you have to know all the MIG welder troubleshooting and its solution.