8-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes | Corrective Actions |
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Welding wire extends too far out of nozzle. | Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. |
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Unsteady hand. | Support hand on solid surface or use two hands. |
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8-15. Troubleshooting − Distortion
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| Distortion − contraction of weld metal during welding that forces |
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| base metal to move. |
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| Base metal moves | |
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| in the direction of | |
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| the weld bead. | |
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Possible Causes |
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| Corrective Actions |
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Excessive heat input. |
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| Use restraint (clamp) to hold base metal in position. |
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| Make tack welds along joint before starting welding operation. |
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| Set Metal Thickness Selector switch to a lower selection. |
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| Increase travel speed. |
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| Weld in small segments and allow cooling between welds. |
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8-16. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem | Probable Cause | Remedy | |
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Wire feed motor operates, but | Too little pressure on wire feed rolls. | Increase pressure setting on wire feed rolls. | |
wire does not feed. |
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Incorrect wire feed rolls. | Check size stamped on wire feed rolls, replace to match | ||
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| wire size and type if necessary. | |
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| Wire spool brake pressure too high. | Decrease brake pressure on wire spool. | |
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| Restriction in the gun and/or assembly. | Check and replace cable, gun, tip adapter, and contact | |
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| tip if damaged. Check size of contact tip and cable liner, | |
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| replace if necessary. | |
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Wire curling up in front of the | Too much pressure on wire feed rolls. | Decrease pressure setting on wire feed rolls. | |
wire feed rolls (bird nesting). |
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Incorrect cable liner or gun contact tip size. | Check size of contact tip and check cable liner length | ||
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| and diameter, replace if necessary. | |
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| Dirty or damaged (kinked) liner. | Replace liner. | |
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Welding arc not stable. | Wire slipping in drive rolls. | Adjust pressure setting on wire feed rolls. Replace worn | |
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| drive rolls if necessary. | |
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| Wrong size gun liner or contact tip. | Match liner and contact tip to wire size and type. | |
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| Incorrect Metal Thickness Selector switch setting on | Change Metal Thickness Selector switch setting. | |
| welding power source. |
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| Loose connections at the gun weld cable or work cable. | Check and tighten all connections. | |
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| Gun in poor shape or loose connection inside gun. | Repair or replace gun as necessary. | |
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| Feed motor bogging down. | Too much feed roll pressure. Loosen tension knob. | |
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