Hobart Welding Products 4500 manual Troubleshooting − Incomplete Fusion

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12-16. 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.

12-17. 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.

12-18. 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 Description OM-4418210 597KProcesses From Hobart to You Table of Contents Page HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peu- vent être dangereux LE Soudage peut provoquer un incendie ou une explosionDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peut Rendre AveugleRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures UNE Remorque QUI Bascule peut entraîner des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF− Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsWeld Amps At Rated Duty Cycle Dimensions, Weights, And Operating AnglesAux Power Gal./Hr Weld Power In KW Fuel ConsumptionDuty Cycle Generator Power CurveAC Power Volts AC Power AmperesAC Amps Volt-Ampere CurvesVolts Max Amp Min Amp Movement − InstallationInstalling Welding Generator Rating Label LocationGrounding Generator To Truck Or Trailer Frame Grounding Generator When Supplying Building SystemsOil Engine Prestart Checks13 mm Full Gasoline Open/On Closed/Off Connecting To Weld Output Terminals 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting to weldSelecting Weld Cable Sizes 150 ft 200 ft 250 ftMaterial Thickness Reference Chart Controls See Section − Operating the Welding GeneratorAmperage Selection Table For Stick Smaw Electrodes To Stop turn engine switch to OffDescription Of Controls See Section X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418 Generator Power Panel Receptacles− Operating Auxiliary Equipment Use GFCI-protected extension cordRoutine Maintenance − MaintenanceStop engine Servicing Air CleanerWelding − TroubleshootingTroubleshooting Generator PowerStarting difficult With proper viscosity oil for operating temperatureEngine Circuit Diagram For Welding Generator − Electrical DiagramsSelecting Equipment − Generator Power GuidelinesResistive Load Volts 115 Amps Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use #10 AWG or larger insulatedFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld TestTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Work like a Pro Main Assembly − Parts ListSR1 Start Your Professional Welding Career Now Assistance ServiceSupport Hobart Welding Products Contact your Distributor for