Miller Electric OM-1313 manual Troubleshooting Excessive Spatter, Troubleshooting Porosity

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6-8.

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.

6-9.

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.

6-10. 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.

OM-1313 Page 26

 

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Contents September Arc Welding Power Source Wire FeederVisit our website at MIG Gmaw Welding Flux Cored Fcaw WeldingFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageMarks a special safety message OM-1313ARC Rays can burn eyes and skin Principal Safety Standards Fire or Explosion hazardEMF Information About PacemakersInstallation SpecificationsVolt-Ampere Curves Welding Gun Duty Cycle And Overheating Welding Power Source Duty Cycle And OverheatingExceeding duty cycle can damage unit and void warranty OverheatingInstalling Work Clamp Installing Gas SupplyPolarity Changeover Label Installing Welding GunSetting Gun Polarity Tools Needed 11/16Reinstall wrapper Tools Needed 7/16 Installing Wire Spool And Adjusting Hub TensionTurn Off unit, and disconnect input power Changing Input VoltageInput Voltage Electrical Service GuideSelecting a Location And Connecting Input Power Min Grounding Conductor Size In AWG/KcmilThreading Welding Wire OM-1313 Operation Front Panel ControlsControls For Standard Units Weld Parameter Chart Higher e.g Volts AC Lower e.g Volts ACOM-1313 Maintenance & Troubleshooting Routine MaintenanceMonths Head Tube Remove nozzle, contact tip, and adapter Cleaning Or Replacing Gun LinerDisconnect gun first Blow out gun casing Remove linerReplacing Switch And/Or Head Tube Remove handle locking nut Slide handleTroubleshooting Replacing Gun Contact TipSee Section Electrical Diagram Circuit DiagramTypical MIG Process Connections Wire Feeder Power Source Gun Work Clamp WorkpieceMIG Welding Gmaw Guidelines Shielding Gas Regulator/ FlowmeterSelect Wire Size Typical MIG Process Control SettingsWire Recommendation Wire Speed Select Voltage Holding And Positioning Welding Gun Perpendicular Drag Conditions That Affect Weld Bead ShapePush Short Normal LongPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting Excessive Penetration Troubleshooting Excessive SpatterTroubleshooting Porosity Possible Causes Corrective ActionsTroubleshooting Lack Of Penetration Troubleshooting Incomplete FusionTroubleshooting Burn-Through Troubleshooting Waviness Of Bead Troubleshooting DistortionWeld bead Troubleshooting Guide For Semiautomatic Welding Equipment Common MIG Shielding GasesApplication Welding power source Welding arc not stable Wire slipping in drive rollsReadjust welding parameters Drive rolls if necessaryOM-1313 Parts List Main AssemblyDia Part Mkgs Description Quantity Center Baffle w/Components Baffle, Center w/Components -1 Item M-15 Gun -1 Item Includes ItemsPage Service Your distributor also givesSupport Owner’s Record
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