DEFECTS IN GMAW OR MIG WELDING

1. Porosity 2. Spatters
3. Lack Of Fusion 4. Under Cut
5. Over Lap 6. Slag
7. Crack 8. Lack Of Penetration
9. Burn Through 10. Convex Bead
11. Unstable Arc 12. Wire Stubbin
 Porosity

Cause
1) Less Mn & Si In Wire
2) Rusted / Unclean BM / Groove
3) Rusted wire
4) Inadequate Shielding Gas
Remedy
1) Use High Mn & Si Wire
2) Clean & warm the BM
3) Replace the Wire
4) Check & Correct Flow Rate

Porosity . .

2
 Spatters
Cause Remedy
1) Low Voltage 1) Increase Voltage
2) Inadequate Inductance 2) Increase Inductance
3) Rusted BM surface 3) Clean BM surface
4) Rusted Core wire 4) Replace By Rust Free wire
5) Quality Of Gas 5) Change Over To Ar + Co2

Spatters
• ••

3
 Lack Of Fusion
Cause Remedy
1) Inadequate Current 1) Use Right Current
2) Inadequate Voltage 2) Use Right Voltage
3) Wrong Polarity 3) Connect Ele. + Ve
4) Slow Travel Speed 4) Increase Travel speed
5) Excessive Oxide On Joint 5) Clean Weld Joint

Lack Of Fusion

4
 Undercut

Cause Remedy
1) Excess Voltage 1) Reduce Voltage
2) Excess Current 2) Reduce Current
3) Improper Torch angle 3) Train & Qualify the Welder
4) Excess Travel Speed 4) Reduce Travel Speed
Under cut

5
 Overlap

Cause Remedy
1) Too Long Stick Out 1) Reduce Stick Out

2) Inadequate Voltage 2) Increase the Voltage

Overlap

6
 Slag
Cause Remedy
1) Inadequate Cleaning 1) Clean each bead
2) Inadequate Current 2) Use Right Current
3) Wrong Torch angle 3) Train / Qualify welder
4) Improper bead placement 4) Train / Qualify Welder

Slag

7
 Crack
Cause Remedy
1) Incorrect Wire Chemistry 1) Use Right Wire
2) Too Small Weld Bead 2) Increase wire Feed
3) Improper Preheat 3) Preheat Uniformly
4) Excessive Restrain 4) Post heating or ISR

crack

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 Lack Of Penetration*
Cause Remedy
1) Too Narrow Groove Angle 1) Widen The Groove
2) Inadequate Root opening 2) Increase Root Opening
3) Too Low Welding current 3) Increase Current
4) Wrong Torch angle 4) Train / Qualify Welder
5) Puddle Roll In Front Of Arc 5) Correct Torch Angle
6) Long Stick Out 6) Reduce Stick Out

* Applicable to SSFPW

LOP
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 Burn through*
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Root opening 2) Reduce root opening
3) Inadequate Root face 3) Increase root face
4) Too Low Travel Speed 4) Increase Speed
5) Quality Of Gas 5) Use Ar + Co2

*Applicable to root pass

Burn trough

10
 Convex Bead Finish
Cause Remedy
1) Low Current 1) Increase Current
2) Low Voltage 2) Increase Voltage
3) Low Travel Speed 3) Increase Travel Speed
4) Low Inductance 4) Increase Inductance
5) Too Narrow Groove 5) Increase Groove Width

Uneven bead finish

11
 Unstable arc

Cause Remedy
1) Improper Wire Feed 1) Check Wire Feeder
2) Improper Gas Flow 2) Check Flow Meter
3) Twisted Torch Conduit 3) Straighten Torch Cab

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 Wire Stubbing

Cause Remedy
1) Too Low Voltage 1) Increase Voltage
2) Too High Inductance 2) Reduce Inductance
3) Excess Slope 3) Adjust Slope
4) Too Long Stick Out 4) Reduce Stick Out

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