Hobart Champion 4500 manual Troubleshooting Incomplete Fusion, Troubleshooting Lack Of Penetration

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11-16. Troubleshooting – Incomplete Fusion

			Incomplete Fusion – failure of weld metal to fuse completely with
			base metal or a preceeding weld bead.




	Possible Causes		Corrective Actions

Insufficient heat input.			Increase amperage. Select larger electrode and increase amperage.

Improper welding technique.			Place stringer bead in proper location(s) at joint during welding.

			Adjust work angle or widen groove to access bottom during welding.

			Momentarily hold arc on groove side walls when using weaving technique.

			Keep arc on leading edge of weld puddle.

Workpiece dirty.			Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
			welding.

11-17. Troubleshooting – Lack Of Penetration

			Lack Of Penetration – shallow fusion between weld metal and
			base metal.

Lack of Penetration			Good Penetration
Possible Causes			Corrective Actions
Improper joint preparation.			Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.			Keep arc on leading edge of weld puddle.
Insufficient heat input.			Increase amperage. Select larger electrode and increase amperage.
			Reduce travel speed.

11-18. Troubleshooting – Excessive Penetration

	Excessive Penetration – weld metal melting through base metal and
	hanging underneath weld.
Excessive Penetration	Good Penetration
Possible Causes	Corrective Actions
Excessive heat input.	Select lower amperage. Use smaller electrode.
	Increase and/or maintain steady travel speed.

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Contents Processes OM-4418210 597ADescription From Hobart to You Table of Contents Page Marks a special safety message Arc Welding HazardsElectric Shock can kill Fumes and Gases can be hazardousEngine Hazards Compressed Air Hazards Principal Safety Standards EMF InformationSignification des symboles Consignes DE Sécurité Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in- cendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut DES Organes Mobiles peuvent provoquer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesSpecifications Symbol DefinitionsWeld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesExceeding duty cycle can damage unit and void warranty Fuel ConsumptionDuty Cycle 100% Duty Cycle at 90 Amperes CC/ACGenerator Power Curve Volt-Ampere CurvesInstalling Welding Generator InstallationGrounding Generator To Truck Or Trailer Frame Grounding Generator When Supplying Building Systems Engine Prestart Checks13 mm Full Gasoline Open Closed OilConnecting To Weld Output Terminals Selecting Weld Cable Sizes45 m 60 m 70 m 90 m 105 m 120 m Put terminalsOperating the Welding Generator Controls See SectionDescription Of Controls See Section To Stop turn engine switch to OffAmperage Selection Table For Stick Smaw Electrodes Generator Power Panel Receptacles Operating Auxiliary EquipmentUse GFCI-protected extension cord 240 V 20 a AC Duplex Receptacle RC1Maintenance Servicing Air Cleaner Clean element by gently tapping on a hard surfaceWashing Precleaner Stop engineTroubleshooting TroubleshootingGenerator Power WeldingEngine With proper viscosity oil for operating temperatureStarting difficult Electrical Diagrams Circuit Diagram For Welding GeneratorGenerator Power Guidelines Selecting EquipmentGrounding When Supplying Building Systems How Much Power Does Equipment Require?Earth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageTypical Connections To Supply Standby Power Work like a ProSelecting Extension Cord Use Shortest Cord Possible Current Load Watts AmperesWeld current starts when electrode touches work- piece Stick Welding ProcedureStick Welding Smaw Guidelines Striking an Arc Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting Porosity Troubleshooting Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting Lack Of Penetration Troubleshooting Incomplete FusionTroubleshooting Excessive Penetration Troubleshooting Waviness Of Bead Troubleshooting Burn-ThroughTroubleshooting Distortion Parts List 35 36Dia Part Description Quantity Mkgs Work like a Pro Page Page Service SupportContact your Distributor for Hobart Welding Products