Hobart Welding Products OM-493 manual Troubleshooting Incomplete Fusion

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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-493Description From Hobart to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards ARC Rays can burn eyes and skinEngine Hazards Engine Exhaust Gases can kill Battery Explosion can BlindMoving Parts can cause injury Engine Heat can cause fireRadiation can cause interference Principal Safety StandardsEMF Information ARC Welding can cause interferenceUN Choc Électrique peut tuer Signification des symbolesConsignes DE Sécurité Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux LE Bruit peut affecter l’ouïeLA Chaleur DU Moteur peut pro- voquer un incendie DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécuritéInformation sur les champs électromagnétiques Consignes relatives aux stimulateurs cardiaquesWeld, Power, and Engine Specifications SpecificationsSymbol Definitions DefinitionsAuxiliary Power Curve Dimensions, Weights, and Operating AnglesDimensions Duty Cycle Exceeding duty cycle can damage unit and void warrantyFuel Consumption Continuous WeldingVolt-Ampere Curve InstallationInstalling Welding Generator Movement Do not lift unit from end Airflow ClearanceEngine Prestart Checks FuelRead and follow all instruc Activating The Dry Charge Battery If ApplicableDo not overfill battery cells ChargerTools Needed 1/2 Connecting the BatteryInstalling Exhaust Pipe Connect negative cable last100 ft 30 m Or Less Connecting to Weld Output TerminalsSelecting Weld Cable Sizes 10 100% Duty CycleOperating the Welding Generator Engine Control SwitchDo not switch under load Front Panel ControlsWeld Current Operating Auxiliary EquipmentStandard Receptacles 120V 240VGfci Receptacle Option Optional Auxiliary Power ReceptaclesGenerator 120 V 20 a AC Gfci RecepMaintenance Maintenance Label Overload Protection Servicing Air CleanerStop engine. Disconnect negative battery cable Stop engineStop engine and let cool Changing Engine Oil, Oil Filter, and Fuel FilterFull Tools Needed Oil Drain Valve 2 ID x 12 in Hose Oil FilterIdle Speed Adjustment Adjusting Engine SpeedWeld/Power Speed Adjustment Servicing Optional Spark Arrestor Welding TroubleshootingAuxiliary Power Trouble RemedySwitch S2, and throttle solenoid TS1 EngineElectrical Diagram Circuit Diagram For Welding GeneratorSelecting Equipment Auxiliary Power GuidelinesGrounding Generator To Truck Or Trailer Frame Earth ground if supplying Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP xTypical Connections To Supply Standby Power 240 120 GroundSelecting 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 Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint 16 in 1.6 mm Tack WeldsWeld Test Troubleshooting PorosityTroubleshooting Excessive Spatter Possible Causes Corrective ActionsTroubleshooting Lack Of Penetration Troubleshooting Incomplete FusionTroubleshooting Excessive Penetration Troubleshooting Waviness Of Bead Troubleshooting Burn-ThroughTroubleshooting Distortion Parts List 12-3Dia Part Description Mkgs Quantity Panel, Front w/Components Panel, Front w/Components -1 Item Generator -1 Item Page Page Service SupportHobart Welding Products Contact your Distributor forCall