12-16. 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 |
| Corrective Actions |
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Insufficient heat input. |
| Increase amperage. Select larger electrode and increase amperage. | |
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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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Workpiece dirty. |
| Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before | |
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| welding. |
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12-17. Troubleshooting − Lack Of Penetration
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| Lack Of Penetration − shallow fusion between weld metal and |
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| base metal. |
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Lack of Penetration | Good Penetration | ||
Possible Causes | Corrective Actions | ||
Improper joint preparation. | Material too thick. Joint preparation and design must provide access to bottom of groove. | ||
Improper weld technique. | Keep arc on leading edge of weld puddle. | ||
Insufficient heat input. | Increase amperage. Select larger electrode and increase amperage. | ||
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| Reduce travel speed. |
12-18. Troubleshooting − Excessive Penetration
| Excessive Penetration − weld metal melting through base metal and |
| hanging underneath weld. |
Excessive Penetration | Good Penetration |
Possible Causes | Corrective Actions |
Excessive heat input. | Select lower amperage. Use smaller electrode. |
| Increase and/or maintain steady travel speed. |
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