A five-year journey with love and dedication. MIG welder troubleshooting guide provides welding troubles and its explanation.
Welding Defects And Causes
Like another welding process, MIG welding has some complications. However, knowing these complications will help you to protect the machine from problems and their solution. Here I’m going to tell you about some common MIG welder troubleshooting, you can boast the quick fix to your welding defects.
Some basic problems of MIG welder are describes as below:
Machine Starting Problem:
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. Moreover, having the problem of starting the machine can cause the overheating.
If you notice that the machine is not starting correctly then you have first check that the machine is appropriately switched. If it is appropriately changed then check the other possible reason and solve them. You must verify that the input voltage is set correctly and follow the manual for avoiding this problem. Alternatively, if the machine gets overheated then shut down it and keep it for cooling down. Alternatively, if the fuse is blown up, then you must replace it as early as possible.
Machine Fuse Blows:
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 the short circuit. Moreover, the other reason may be the wick is too small for the machine.
Noticing this problem, you have to solve the short circuit. Alternatively, 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:
If the polarity switch is worn out or the welder is under load then the polarity switch stops working.
Noticing this problem, you must change the polarity switch and make sure that you are not using the welder at under load condition.
Electrode Holder’s Excess Heats up:
If there has a loose connection or have set an irregular duty cycle then the electrode holder will heat up.
To solve this problem you must tight the connection. Alternatively, if causes by irregular duty cycle then you have to change that with the proper size.
If you are not grounded the frame of the welder machine properly then it may cause the electrical shocks.
In this case, you have to follow the manual and instruction of grounding the frame properly to avoid electrical shocks. If you ground the chassis correctly, then you will not face any electrical shocks.
Excess Heat Of Welding Cable:
If the cable is in a defective condition or the duty cycle is improper then the wire will heat up very faster.
For avoiding this problem you must change the cable with proper condition and size. Moreover, you will know the appropriate scope of wire in the user manual.
Ground Clamp Turns Bad:
When the machine gets implicated by oxides that can change the flow of current and can create high stumbling block of the machine then the ground clamp will be in lousy condition.
Make sure that you are cleaning the ground clamp regularly for avoiding the building up of oxides that cause the creation of stumbling block of the machine.
If you are using the cable for a long time then it can damage.
If you notice that the cable is in damaged condition then you must change it instantly otherwise it will affect your working quality and also create a problem.
If you notice any poor welding result then you may replace or repair the parts of the welder. Because poor welding result only causes defective portions of the machine. Below is given some common welding defects and its solution.
Inappropriate Wire Feeding:
A widespread welding defect may cause by inappropriate MIG welder wire feed problems that are occurred by worn driver rolls.
Clean the driver roll periodically and remove all the dirt of the liner for avoiding this problem. Moreover, replace the driver roll if it’s necessary.
When the welding gun’s tip worn out then it can cause the flat welding. If it happens suddenly, you won’t get proper welding result.
You must replace the tip just after noticing this problem.
Another common welding defect is porosity. Insufficient gas flow occurs it.
For avoiding this problem you must check that gas nozzle is plugged in correctly. Moreover, also check that the wire connection is plugged in correctly.
Shrinkage Crash On The Weld:
If the wire is pale or having small follicle can cause shrinkage crash on the weld.
If the follicle is of sufficient size then you won’t face this problem. Moreover, always remember that there is no rust in the welding area.
Lateral Cracks On The Weld:
Lateral cracks on the weld can occur by the fast welding speed or low current or high arc voltage.
For avoiding Lateral cracks on the weld, maintain a constant welding speed. Moreover, make sure that the arc voltage is also constant.
Excess spatter is widespread welding defects. It can be caused by high voltage or excess CO2 or improper impedance.
By using a gas heater you can avoid this problem. You can also 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. Also, a surface which is open in the atmospheric air also causes metal porosity.
For avoiding the contaminated surface, clean the material at the following methods.
B) Absorbency Problem
Inappropriate gas shield can also cause 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.
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 of base metal creates another common porosity problem. For example, you are not using same baking bar material of the metal that you are welding.
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 bead problem.
For avoiding this problem, set the input power correctly according to the thickness of metal.
B) Inappropriate Bead Problem
Using wrong technique in welding can cause bead problem.
For avoiding this problem, you must adopt the right technique of welding.
C) Inappropriate Bead Problem
Insufficient Work Cable:
Using small cable in welding will cause bead problem.
Use the appropriate size of cable to avoid this problem.
3. Fusion Shortage
Fusion Shortage Problem
The lacking of fusion occurs cold lapping. In this method, the wire straightly touches the welding pool and melts the wire.
For avoiding the cold lapping you must check that the voltage and amperage are in the right form.
4. Defective Wire Delivery
A) Defective Wire Delivery Problem
The contact tips can occur faulty wire delivery. Moreover, the contact tips can get obstructed by the overplus of spatter or by touching on the welding puddle.
You can solve this problem by just changing the contact tips. However, you must remember one thing that you are using the right size of contact tips.
B) Defective Wire Delivery Problem
Inappropriate size of the gun liner can cause the short wire delivery. It also creates by extending wire.
To avoid this problem you have to use proper size of gun liner. Also, make sure that you are cleaning the gun liner regularly to keep them free from dust. You also have to change the ships frequently.
C) Defective Wire Delivery Problem
Worn Out Gun:
Worn out gun also can create wire feeding problem.
After noticing this problem, you must replace or change the worn out gun instantly.
D) Defective Wire Delivery Problem
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.
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
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.