Miller Electric M-10 Gun manual Troubleshooting − Excessive Spatter, Troubleshooting − Porosity

Page 43

8-8.

Troubleshooting − Excessive Spatter

 

 

Excessive Spatter − scattering of molten metal particles that

 

 

cool to solid form near weld bead.

 

 

S-0636

 

Possible Causes

Corrective Actions

Wire feed speed too high.

Select lower wire feed speed.

Voltage too high.

Select lower voltage range.

Electrode extension (stickout) too long.

Use shorter electrode extension (stickout).

Workpiece dirty.

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

Insufficient shielding gas at welding arc.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire.

Use clean, dry welding wire.

 

 

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

8-9.

Troubleshooting − Porosity

 

 

Porosity − small cavities or holes resulting from gas pockets

 

 

in weld metal.

 

 

S-0635

 

Possible Causes

Corrective Actions

Insufficient shielding gas at welding arc.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

 

 

Remove spatter from gun nozzle.

 

 

Check gas hoses for leaks.

 

 

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

 

 

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas.

Use welding grade shielding gas; change to different gas.

Dirty welding wire.

Use clean, dry welding wire.

 

 

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty.

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

 

 

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle.

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

8-10.

Troubleshooting − Excessive Penetration

 

 

Excessive Penetration − weld metal melting through base metal

 

 

and hanging underneath weld.

 

Excessive Penetration Good Penetration

 

 

S-0639

 

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

 

 

Increase travel speed.

 

 

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Contents File MIG Gmaw OM-1330220 237HProcesses DescriptionFrom Miller to You Table of Contents − Parts List Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding HazardsBuildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyesCalifornia Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Pacemakers LES Fumées ET LES GAZ peuvent être dangereux UNE Décharge Électrique peut entraîner la mortIndique un message de sécurité particulier DES Pièces Chaudes peuvent provoquer des brûlures graves LE Soudage peut provoquer unIncendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut SUREn ce qui concerne les stimulateurs cardiaques Principales normes de sécurité115 VAC Symbols And DefinitionsSpecifications General SpecificationsOverheating Duty Cycle And OverheatingMIG Welding Gun Duty Cycle And Overheating Volt-Ampere CurvesDefinition Installing Work Clamp Connecting To Weld Output TerminalsSetting Gun Polarity For Wire Type Installing Welding GunRear Panel Installing Gas SupplyInstalling 1 Or 2 lb Wire Spool Installing MIG Wire Spool and Adjusting Hub TensionConnecting 1-Phase Input Power For 230 VAC Hz Single Phase Electrical Service Guide For 230 VACExtension Cord Data Do not move or operate unit where it could tip Selecting a Location And Connecting Input PowerScale Threading Welding WireTurn Off unit, and disconnect input power Installing Diverter Valve And Switch For Optional Spool GunOperation End of hose Connecting An Optional Spool GunControls − OperationOM-1330 Weld Parameter Chart 220 493-A Supplementary Protector CB1 Routine MaintenanceMonths Replacing Gun Contact Tip Changing Drive Roll and Wire Inlet GuideTurn Off power Unit OverloadRemoving Knob From Front Panel Aligning Drive Rolls and Wire GuideDisconnect gun from unit Cleaning Or Replacing Gun LinerTo Reassemble Gun Disconnect gun first Replacing Switch And/Or Head TubeWelding Trouble Remedy Troubleshooting− Electrical Diagram 220 197-E Typical MIG Process Connections − MIG Welding Gmaw GuidelinesSelect Voltage Typical MIG Process Control SettingsWire Recommendation Wire Speed Select Wire SizeHolding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Good Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Excessive PenetrationTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Burn-Through Troubleshooting − Distortion Troubleshooting − Waviness Of BeadApplication Troubleshooting Guide For Semiautomatic Welding EquipmentWire does not feed Common MIG Shielding GasesWelding arc not stable Wire slipping in drive rolls − Parts List CABLE,POWER 12 FT 5 in 12GA 4C Soow W/SPL Plug Baffle, Center w/Components Baffle, Center w/Components -1Item Panel, Rear w/Components Panel, Front w/Components 204857 See Section Drive Roll & Wire Guide KitsM-10 Gun 207 Optional Spoolmate Spool Gun Switch Drive Roll And Wire Guide KitsPage Page Support ServiceMiller Electric Mfg. Co Owner’s Record
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