Hobart Welding Products 4500 manual Troubleshooting − Incomplete Fusion, Possible Causes

12-16. Troubleshooting − Incomplete Fusion

		Incomplete Fusion − failure of weld metal to fuse completely with
		base metal or a preceeding weld bead.
	Possible Causes	Corrective Actions
Insufficient heat input.		Increase amperage. Select larger electrode and increase amperage.
Improper welding technique.		Place stringer bead in proper location(s) at joint during welding.
		Adjust work angle or widen groove to access bottom during welding.
		Momentarily hold arc on groove side walls when using weaving technique.
		Keep arc on leading edge of weld puddle.
Workpiece dirty.		Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
		welding.

12-17. Troubleshooting − Lack Of Penetration

		Lack Of Penetration − shallow fusion between weld metal and
		base metal.
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.
		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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