Miller Electric 172 M-10 Gun manual Troubleshooting Excessive Spatter, Troubleshooting Porosity

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7-8.

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.

7-9.

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.

7-10. 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 OM-1318187923F ProcessesDescription From Miller to You Table of Contents Page Marks 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 killPrincipal Safety Standards About Pacemakers EMF InformationConsignes DE Securite Lire Avant Utilisation Signification des symbolesUN Choc É Lectrique peut tuer LES Fumé ES ET LES GAZ peuvent ê tre dangereuxLE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxLE Bruit peut affecter l’ouïe LA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessuresPrincipales normes de sé curité Information sur les champs é lectromagné tiquesConsignes relatives aux stimulateurs cardiaques Specifications SpecificationsVolt-Ampere Curves Welding Gun Duty Cycle And Overheating Welding Power Source Duty Cycle And OverheatingOverheating DefinitionInstallation Installing Work ClampInstalling Welding Gun And Changing Polarity Flow Adjust Installing Gas SupplySelecting a Location And Connecting Input Power Electrical Service GuideDo not move or operate unit Where it could tip 18 in 457 mm of space for airflowInstalling Wire Spool And Adjusting Hub Tension Standard Wire Spool Standard Wire ReelTools Needed 15/16 Reinstall contact tip, and nozzle Assembly, and let go of wire14 ga 16 ga 18 ga 20 ga 22 ga Weld ParameterVoltage Switch Wire Speed ControlOperation ControlsRoutine Maintenance Maintenance &TROUBLESHOOTINGDrive Motor Fuse F1 Short Circuit ShutdownTurn Off power before cleaning or repairing drive assembly Cleaning Or Repairing Drive AssemblyWire Spool Nozzle Turn Off power before replacing contact tipDisconnect gun from unit Cleaning Or Replacing Gun LinerBlow out gun casing Tools Needed Remove liner To Reassemble GunReplacing Switch And/Or Head Tube Disconnect gun firstRemove handle locking nut Slide handle Secure power cord plug in receptacle see Section Troubleshooting TableTrouble Remedy Motor continues to run SectionOM-1316 Electrical DiagramMIG Welding Gmaw Guidelines Regulator Flowmeter Wire Feeder Power Source Shielding GasTypical MIG Process Connections Gun Workpiece Work ClampWire Recommendation Wire Speed Typical MIG Process Control SettingsSelect Wire Size Based on 1/8 in material thickness Ipm = inch per minute Holding And Positioning Welding Gun Push PerpendicularDrag Conditions That Affect Weld Bead ShapeShort Normal Long ShortNormalLongPoor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting Porosity Troubleshooting Excessive SpatterTroubleshooting Excessive Penetration Possible Causes Corrective ActionsTroubleshooting Lack Of Penetration Troubleshooting Incomplete FusionTroubleshooting Burn-Through Troubleshooting Waviness Of Bead Troubleshooting DistortionWeld bead Common MIG Shielding Gases ApplicationFlat & Horizontal1 Fillet OM-1318 Includes Items Parts ListDia Part Description Mkgs Quantity M-10 Gun Figure -2. M-10 Gun Page Service Your distributor also givesSupport Miller Electric Mfg. Co Owner’s Record
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