9-11. Troubleshooting − Excessive Penetration
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| Excessive Penetration − weld metal melting through base metal |
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| and hanging underneath weld. |
Excessive Penetration | Good Penetration | |||
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Possible Causes |
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| Corrective Actions |
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Excessive heat input. |
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| Select lower voltage range and reduce wire feed speed. | |
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| Increase travel speed. | |
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9-12. Troubleshooting − Lack Of Penetration
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| Lack Of Penetration − shallow |
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| fusion between weld metal and |
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| base metal. |
Lack of Penetration | Good Penetration | ||||
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Possible Causes |
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Improper joint preparation. |
| Material too thick. Joint preparation and design must provide access to bottom of groove while | |||
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| maintaining proper welding wire extension and arc characteristics. | |
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Improper weld technique. |
| Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration. |
| Keep arc on leading edge of weld puddle. |
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| Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. |
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Insufficient heat input. | Select higher wire feed speed and/or select higher voltage range. |
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| Reduce travel speed. |
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Incorrect polarity. | Check polarity required by welding wire, and change to correct polarity at welding power source. |
9-13. Troubleshooting − Incomplete Fusion
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| Incomplete Fusion − failure of weld metal to fuse completely with |
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| base metal or a preceeding weld bead. |
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Possible Causes |
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Workpiece dirty. |
| Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before | ||
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| welding. | |
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Insufficient heat input. |
| Select higher voltage range and/or adjust wire feed speed. | ||
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Improper welding technique. |
| Place stringer bead in proper location(s) at joint during welding. | ||
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| Adjust work angle or widen groove to access bottom during welding. | |
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| Momentarily hold arc on groove side walls when using weaving technique. | |
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| Keep arc on leading edge of weld puddle. | |
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| Use correct gun angle of 0 to 15 degrees. | |
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