Hobart Welding Products 4500 manual Weld Test, Troubleshooting − Porosity

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12-13. Weld Test

2 To 3 in

(51-76 mm)

1/4 in (6.4 mm)

3
	3
	2 To 3 in
	(51-76 mm)
2	2
2
1	1

1Vise

2Weld Joint

3Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

S-0057-B

12-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Causes	Corrective Actions

Arc length too long.	Reduce arc length.

Damp electrode.	Use dry electrode.

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

12-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes	Corrective Actions

Amperage too high for electrode.	Decrease amperage or select larger electrode.

Arc length too long or voltage too high.	Reduce arc length or voltage.

OM-4418 Page 42

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Contents Processes OM-4418210 597KDescription From Hobart to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LE Soudage peut provoquer un incendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peu- vent être dangereux LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut Rendre Aveugle DES Organes Mobiles peuvent provoquer des blessures’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures UNE Remorque QUI Bascule peut entraîner des blessuresInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité En ce qui concerne les implants médicauxWeld, Power, And Engine Specifications − SpecificationsSymbol Definitions − DefinitionsFuel Consumption Dimensions, Weights, And Operating AnglesAux Power Gal./Hr Weld Power In KW Weld Amps At Rated Duty CycleAC Power Amperes Generator Power CurveAC Power Volts Duty CycleVolts Max Amp Min Amp Volt-Ampere CurvesAC Amps Rating Label Location − InstallationInstalling Welding Generator MovementGrounding Generator When Supplying Building Systems Grounding Generator To Truck Or Trailer Frame13 mm Full Gasoline Open/On Closed/Off Engine Prestart ChecksOil Connecting To Weld Output Terminals 150 ft 200 ft 250 ft Connecting to weldSelecting Weld Cable Sizes 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mMaterial Thickness Reference Chart − Operating the Welding Generator Controls See SectionDescription Of Controls See Section To Stop turn engine switch to OffAmperage Selection Table For Stick Smaw Electrodes Use GFCI-protected extension cord Generator Power Panel Receptacles− Operating Auxiliary Equipment X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418− Maintenance Routine MaintenanceServicing Air Cleaner Stop engineGenerator Power − TroubleshootingTroubleshooting WeldingEngine With proper viscosity oil for operating temperatureStarting difficult − Electrical Diagrams Circuit Diagram For Welding Generator− Generator Power Guidelines Selecting EquipmentUse #10 AWG or larger insulated Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Resistive Load Volts 115 AmpsIndustrial 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 x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw GuidelinesStriking 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 30 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 Work like a Pro − Parts List Main AssemblySR1 Start Your Professional Welding Career Now Support ServiceAssistance Contact your Distributor for Hobart Welding Products