Troubleshooting − Incomplete Fusion | Miller Electric Blue Star 145

13-16. 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.

13-17. 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.

13-18. 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.

OM-4417 Page 47

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Miller Electric Blue Star 145, 145 DXR, 145 Troubleshooting − Incomplete Fusion, Troubleshooting − Lack Of Penetration

Contents

File Engine Drive OM-4417210 403FProcesses Description From Miller to You Table of Contents Page HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine Specifications Dimensions, Weights, And Operating Angles DimensionsVolt-Ampere Curves Fuel Consumption Minutes Welding Generator Power CurveDuty Cycle 100% Duty Cycle at 80 Amperes CC/DC Hazards − InstallationInstalling Welding Generator Movement Grounding Generator When Supplying Building Systems Engine Prestart Checks − Standard ModelOil Engine Prestart Checks − DX Model Connecting The Battery DX Models Only Put terminals Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 m 10 − Controls Standard Models See Section − Operating the Welding Generator Description Of Controls Standard Models See Section Stop engine and add oil if light goes on see SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary EquipmentAC Receptacle RC1 Routine Maintenance − Maintenance Standard Model Shown Servicing Air CleanerPrecleaner Paper Element Stop engine Tools Needed Adjusting Engine Speed Standard Models OnlyStop Engine Close Valve Adjusting Engine Speed DX Models Only Weld/Power Speed AdjustmentIdle Speed Adjustment Welding − TroubleshootingTroubleshooting Generator Power Engine − Parts List Recommended Spare PartsRecommended Spare Parts Circuit Diagram For Standard Models − Electrical Diagrams Circuit Diagram for DX Models − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building Systems Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes − Stick Welding Smaw Guidelines Stick Welding Procedure Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Electrode Movement During Welding Conditions That Affect Weld Bead Shape 16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee Joint Possible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld Test Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact