9-15. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

S-0641

Possible Causes

Corrective Actions

 

 

Welding wire extends too far out of nozzle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

 

 

Unsteady hand.

Support hand on solid surface or use two hands.

 

 

9-16. Troubleshooting − Distortion

 

 

 

Distortion − contraction of weld metal during welding that forces

 

 

 

base metal to move.

 

 

Base metal moves

 

 

 

 

 

in the direction of

 

 

the weld bead.

 

 

 

S-0642

 

 

 

 

Possible Causes

 

 

Corrective Actions

 

 

 

 

Excessive heat input.

 

 

Use restraint (clamp) to hold base metal in position.

 

 

 

 

 

 

 

Make tack welds along joint before starting welding operation.

 

 

 

 

 

 

 

Select lower voltage range and/or reduce wire feed speed.

 

 

 

 

 

 

 

Increase travel speed.

 

 

 

 

 

 

 

Weld in small segments and allow cooling between welds.

 

 

 

 

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem

Probable Cause

Remedy

 

 

 

Wire feed motor operates, but

Too little pressure on wire feed rolls.

Increase pressure setting on wire feed rolls.

wire does not feed.

 

 

Incorrect wire feed rolls.

Check size stamped on wire feed rolls, replace to match

 

 

 

wire size and type if necessary.

 

 

 

 

Wire spool brake pressure too high.

Decrease brake pressure on wire spool.

 

 

 

 

Restriction in the gun and/or assembly.

Check and replace cable, gun, tip adapter, and contact

 

 

tip if damaged. Check size of contact tip and cable liner,

 

 

replace if necessary.

 

 

 

Wire curling up in front of the

Too much pressure on wire feed rolls.

Decrease pressure setting on wire feed rolls.

wire feed rolls (bird nesting).

 

 

Incorrect cable liner or gun contact tip size.

Check size of contact tip and check cable liner length

 

 

 

and diameter, replace if necessary.

 

 

 

 

Gun end not inserted into drive housing properly.

Loosen gun securing bolt in drive housing and push gun

 

 

end into housing just enough so it does not touch wire

 

 

feed rolls.

 

 

 

 

Dirty or damaged (kinked) liner.

Replace liner.

 

 

 

Welding arc not stable.

Wire slipping in drive rolls.

Adjust pressure setting on wire feed rolls. Replace worn

 

 

drive rolls if necessary.

 

 

 

 

Wrong size gun liner or contact tip.

Match liner and contact tip to wire size and type.

 

 

 

 

Incorrect voltage setting for selected wire feed speed on

Readjust welding parameters.

 

welding power source.

 

 

 

 

 

Loose connections at the gun weld cable or work cable.

Check and tighten all connections.

 

 

 

 

Gun in poor shape or loose connection inside gun.

Repair or replace gun as necessary.

 

 

 

OM-947 Page 39

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Hobart Welding Products OM-947 manual Troubleshooting − Waviness Of Bead, Troubleshooting − Distortion

OM-947 specifications

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