Miller Electric 140, M-10 Gun, 180 Troubleshooting − Excessive Spatter, Troubleshooting − Porosity

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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.

Wrong polarity.

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

 

recommended polarity, and see Section 4-5.

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.

Wrong polarity.

Configure polarity as shown in Section 4-5. Always read and follow wire manufacturer’s

 

recommended polarity, and see Section 4-5.

OM-225 311 Page 49

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Contents Processes OM-225 311CDescription File MIG GmawFrom Miller to You Table of Contents − Parts List − Maintenance &TROUBLESHOOTINGMarks a special safety message Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion ARC Rays can burn eyes and skinFlying Metal can injure eyes Buildup of GAS can injure or killCalifornia Proposition 65 Warnings About Pacemakers Principal Safety StandardsEMF Information Indique un message de sécurité particulier UNE Décharge Électrique peut entraîner la mortLES Fumées ET LES GAZ peuvent être dangereux DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un incendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut endommager l’ouïeLA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU D’EXPLO’EMPLOI Excessif peut SUR DES Organes Mobiles peuvent provoquer des blessuresEn ce qui concerne les stimulateurs cardiaques Principales normes de sécuritéSpecifications − SpecificationsVAC Model VAC Model w/Auto−SetE115 VAC Model Duty Cycle And Overheating230 VAC Model OverheatingAmperage Volt-Ampere CurvesIncorrect − InstallationInstalling Welding Gun Changing Polarity Work Cable Routing Inside UnitProcess/Polarity Table Installing Gas Supply Required where gasoline or Special installation may beVolatile liquids are present − See NEC Article 511 or CECDo not move or operate unit where it could tip Input Voltage 230 Input Amperes At Rated Output Electrical Service Guide For 230 VAC ModelInstalling Wire Spool And Adjusting Hub Tension Remove gun nozzle and contact tip Threading Welding WireEnd Of Wire To Spool Removing MIG Gun From Welding Power SourceCut Off End Of Wire Open Pressure Assembly Knob Operation Installing Optional Spool Gun Switch In Welding Power SourceConnecting Spool Gun To Millermatic 140/180 Controls For 115 VAC Model w/Auto-SetE − Operation115V Controls For 115 VAC Model230V Controls For 230 VAC ModelOM-225 311 Weld Parameter Chart For 115 VAC Model w/Auto−SetE 10/90 10/65 10/80 10/60 10/50 10/95 10/75 10/100 Aluminum 100% Argon 4043ER 030 0.8 mm 035 0.9 mm10/32 OM-225 311 10/90 10/45 10/60 10/30 10/32 10/80 035 0.9 mm 030 0.8 mm#220179 #202926 #220179Dcep Dcen 024 0.6 mm #220179 030 0.8 mm #202926 035 0.9 mm 045 1.2 mm 100 10/60 10/45 10/40 10/20 10/50Routine Maintenance − Maintenance &TROUBLESHOOTINGOverload Protection Drive Motor ProtectionReplacing Gun Contact Tip Changing Drive Roll Or Wire Inlet GuideTurn Off power before replacing contact tip To Reassemble Gun Cleaning Or Replacing Gun LinerDisconnect gun from unit Replacing Switch And/Or Head Tube Trouble Remedy Troubleshooting TableOM-225 311 Circuit Diagram − Electrical Diagram234 419-B Typical MIG Process Connections − MIG Welding Gmaw GuidelinesWire Recommendation Wire Speed Typical MIG Process Control SettingsSelect Wire Size Select Voltage Holding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Gun Movement During Welding Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Incomplete Fusion Troubleshooting − Excessive PenetrationTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Flat & Horizontal1 Fillet Common MIG Shielding GasesApplication Recommended Spare Parts − Parts ListOptional Drive Rolls OptionsPage Support ServiceMiller Electric Mfg. Co Owner’s Record
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