COMMON WELDING PROBLEM 

TIP 1
Problem:  Undercutting

Why
1. Faulty electrode manipulation
2. Welding current too high
3. Too long an arc length
4. Too fast a travel speed
5. Arc blow

What to do
1.  Pause  at each side of the weld bead when using a weaving technique.
2.  Use proper electrode angles.
3.  Use  proper welding current for electrode size and welding position
4.  Reduce arc length.
5.  Reduce travel speed.
6.  Reduce effects of arc blow

TIP 2
Problem:  Lack of Fusion

Why
1. Improper travel speed.
2.  Welding current too low.
3.  Faulty joint preparation.
4. Too large an electrode diameter.
5.  Magnetic arc blow.
6.  Wrong electrode angle. 

What to do
1.  Reduce travel speed.
2.  Increase welding current.
3.  Weld design should allow electrode accessibility to all surfaces within the joint.
4.  Reduce electrode diameter.
5.   Reduce effects of magnetic arc blow.
6.  Use proper electrode angles.   

TIP 3
Problem:  Distortion 

Why
1.  Improper tack welding and/or faulty joint preparation.
2.  Improper bead sequencing.
3.  Improper set-up and fixturing.
4.  Excessive weld size. 

What to do
1.  Tack weld parts with allowance for distortion.
2.  Use proper bead sequencing.
3.  Tack or clamp parts securely.
4.  Make welds to specified size. 

"Causes and Cures of Common Welding Problems."  Pocket Welding Guide.  27th edition.  Available from  Hobart Institute of Welding Technology; Training Materials Department;   1-800-332-9448,   ext.  5433  or http://www.welding.org.  E-mail:  hiwt@welding.org