Troubleshooting − Excessive Spatter | Hobart Welding Products 250

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-192 440 Page 35

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Hobart Welding Products 250 installation instructions Troubleshooting − Excessive Spatter, Troubleshooting − Porosity

Contents

File MIG Gmaw OM-192 440WProcesses Description From Hobart to You Table of Contents Warranty Electric Shock can kill Symbol UsageMarks a special safety message Arc Welding Hazards Buildup of GAS can injure or kill ARC Rays can burn eyes and skinWelding can cause fire or explosion Flying Metal can injure eyes California Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Pacemakers UNE Décharge Électrique peut entraîner la mort LES Fumées ET LES GAZ peuvent être dangereuxIndique 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 yeux DES Organes Mobiles peuvent provoquer des blessures Risque D’INCENDIE OU D’EXPLOLA Chute DE L’APPAREIL peut blesser ’EMPLOI Excessif peut SUR En ce qui concerne les stimulateurs cardiaques Principales normes de sécurité Overheating SpecificationsWelding Power Source Duty Cycle And Overheating Exceeding duty cycle can damage unit and void warranty Welding Gun Duty Cycle And Overheating Volt-Ampere CurvesDefinition Installing Welding Gun Installing Work Clamp Connecting To Weld Output Terminals Installing Wire Spool And Adjusting Hub Tension Setting Gun Polarity For Wire Type Rear Panel Installing Gas Supply Volts Positioning Jumper Links Min Grounding Conductor Size In AWG Electrical Service GuideHz Single Input Voltage Selecting a Location And Connecting Input Power Wood Threading Welding Wire Operation Turn Off unit, and disconnect input power Turn Off unit Connecting Spool Gun To Welding Power Source Controls − Operation Voltage switch position Weld ParametersWhile welding To read settings Example 2/40 =Number on left of slash Months Routine MaintenanceDisconnect power before maintaining Supplementary Protectors Replacing Drive Roll And Wire Inlet Guide Turn Off powerRemoving Knob From Front Panel Replacing Gun Contact Tip Turn Off power before replacing contact tip Wire size stamped on tip − check and match wire size Turn off welding power source/wire feeder Replacing Switch And/Or Head Tube Welding Trouble Remedy Welding Troubleshooting TableWire Drive/Gun Troubleshooting Table Wire Drive/Gun Trouble Remedy Typical MIG Process Connections − MIG Welding Gmaw Guidelines Amperage Typical MIG Process Control SettingsWire Size Amperage Range Thickness to Amperage a Holding And Positioning Welding Gun Conditions That Affect Weld Bead Shape Poor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Possible Causes Corrective Actions Troubleshooting − Excessive SpatterTroubleshooting − Porosity Troubleshooting − Excessive Penetration Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Troubleshooting − Distortion Troubleshooting − Waviness Of Bead Application Troubleshooting Guide For Semiautomatic Welding EquipmentWire does not feed Common MIG Shielding Gases Welding arc not stable Wire slipping in drive rolls OM-192 440 − Electrical Diagram − Parts List REGULATOR/FLOWMETER, 10−50 CFH ARGON/CO2 Center Baffle w/Components Center Baffle w/Components -1Item Rear Panel w/Components Front Panel w/Components M-25 Gun Description Remarks Optional Spool Gun SwitchPage Service SupportAssistance Hobart Welding Products Contact your Distributor for