Hobart Welding Products 230 Troubleshooting − Lack Of Penetration, Troubleshooting − Burn-Through

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6-11. Troubleshooting − Lack Of Penetration

 

 

 

 

 

Lack Of Penetration − shallow

 

 

 

 

 

 

 

 

 

 

fusion between weld metal and

 

 

 

 

 

 

 

 

base metal.

Lack of Penetration

Good Penetration

 

 

 

 

 

S-0638

 

 

 

 

Possible Causes

 

 

Corrective Actions

 

 

 

Improper joint preparation.

 

Material too thick. Joint preparation and design must provide access to bottom of groove while

 

 

 

 

maintaining proper welding wire extension and arc characteristics.

 

 

 

Improper weld technique.

 

Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

 

Keep arc on leading edge of weld puddle.

 

 

 

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

 

 

Insufficient heat input.

Select higher wire feed speed and/or select higher voltage range.

 

 

 

Reduce travel speed.

 

 

Incorrect polarity.

Check polarity required by welding wire, and change to correct polarity at welding power source.

6-12. Troubleshooting − Incomplete Fusion

 

 

Incomplete Fusion − failure of weld metal to fuse completely with

 

 

base metal or a preceeding weld bead.

 

 

S-0637

 

 

 

 

 

 

 

Possible Causes

 

Corrective Actions

 

 

 

Workpiece dirty.

 

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before

 

 

welding.

 

 

 

Insufficient heat input.

 

Select higher voltage range and/or adjust wire feed speed.

 

 

 

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.

 

 

 

 

 

Use correct gun angle of 0 to 15 degrees.

 

 

 

6-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

S-0640

Possible Causes

Corrective Actions

 

 

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

 

 

 

Increase and/or maintain steady travel speed.

 

 

OM-235 281 Page 37

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Contents Processes OM-235 281ADescription File MIG GmawProtect Your Investment From Hobart to YouTable of Contents Warranty Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can burnARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyesFire or Explosion hazard Welding Wire can injureFalling Equipment can injure Moving Parts can injureCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésLE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO- Sion LA Chute DE L’APPAREIL peut blesserLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsLES Fils DE Soudage peuvent provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformation EMF OM-235 281 Overheating SpecificationsWelding Power Source Duty Cycle And Overheating Voltage Volt-Ampere CurvesAmperage 40.0 35.0 30.0 25.0 20.0 15.0 10.0 100 150 200 250 300MIG GUN Installing Welding GunInstalling Work Clamp Connecting To Weld Output TerminalsInstalling 2 lb Wire Spool And Adjusting Hub Tension Setting Gun Polarity For Wire TypeChanging Polarity Electrode Negative DcenInstalling 33 lb Wire Spool And Adjusting Hub Tension Installing 10 lb Wire Spool And Adjusting Hub TensionTools Needed 1-1/8, 5/8 Installing Gas SupplyRear Panel Positioning Jumper Links Turn off and disconnect input powerHz Single Electrical Service GuideInput Voltage Input Amperes At Rated OutputDo not move or operate unit where it could tip Selecting a Location And Connecting Input PowerSpecial installation may be Conductors from unitThreading Welding Wire Turn Off unit, and disconnect input power 3070 2080 1090 Wire Speed ControlControls Weld Parameters Selecting Wire, Gas and Control SettingsDisconnect power Routine MaintenanceSupplementary Protectors Before maintainingRemoving Knob From Front Panel Replacing Drive Roll And Wire Inlet GuideTurn Off power Replacing Gun Contact Tip Aligning Drive Rolls and Wire GuideTurn Off power before replacing contact tip Cable Hanger Screws Tools Needed Installing Cable HangersTurn Off power before Installing cable hangers Turn off welding power source/wire feeder Wire Drive/Gun Troubleshooting Table Welding Troubleshooting TableWire Drive/Gun Trouble Remedy Welding Trouble RemedyTypical MIG Process Connections − MIG Welding Gmaw GuidelinesWire Size Amperage Range Typical MIG Process Control SettingsAmperage Select VoltageGroove Welds Holding And Positioning Welding GunPush Conditions That Affect Weld Bead ShapePerpendicular Drag Short Normal LongGun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective ActionsTroubleshooting − Burn-Through Troubleshooting − Lack Of PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Distortion Troubleshooting − Waviness Of BeadBase metal to move DirectionApplication Troubleshooting Guide For Semiautomatic Welding EquipmentCommon MIG Shielding Gases Readjust welding parameters Welding arc not stable Wire slipping in drive rollsWelding power source Drive rolls if necessary− Electrical Diagram 10 − Fig 17 − Fig Main AssemblyItem Dia Part Description Quantity Mkgs Center Baffle w/Components Center Baffle w/Components -1Item Rear Panel w/Components Front Panel w/Components 234 Wire Drive Assembly Wire Drive Assembly237 H200L4−15 GunKnurl Drive Roll For Hard Shell Cored Wires AccessoriesAssistance ServiceSupport Hobart Welding Products Contact your Distributor for