Weld Test, Troubleshooting − Porosity

13-13. Weld Test

2 To 3 in

(51-76 mm)

1/4 in (6.4 mm)

3
	3
	2 To 3 in
	(51-76 mm)
2	2
2
1	1

1Vise

2Weld Joint

3Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

S-0057-B

13-14. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets in weld metal.

Possible Causes	Corrective Actions

Arc length too long.	Reduce arc length.

Damp electrode.	Use dry electrode.

Workpiece dirty.	Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
	welding.

13-15. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes	Corrective Actions

Amperage too high for electrode.	Decrease amperage or select larger electrode.

Arc length too long or voltage too high.	Reduce arc length or voltage.

OM-4415 Page 48

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Image 52

Miller Electric 185 DX manual Weld Test, Troubleshooting − Porosity, Troubleshooting − Excessive Spatter

Contents

OM-4415 ProcessesDescription File Engine Drive From Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference − Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion ’EXPLOSION DE LA Batterie peu LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent pro voquer des blessures ’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peut Principales normes de sécurité Proposition californienne 65 AvertissementsInformation EMF − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − Definitions Dimensions, Weights, And Operating Angles DimensionsDuty Cycle 100% Duty Cycle at 100 Amperes CC/DC Standard Model Honda Engine Volt-Ampere CurvesDX Model Kohler Engine Auxiliary Power DX Model Kohler Engine Auxiliary Power Standard Model Honda EngineFuel Consumption Curves Power Output Standard Model Honda Engine Generator Power CurvesPower Output DX Model Kohler Engine − Installation Installing Welding GeneratorMovement Hazards Grounding Generator When Supplying Building Systems Engine Prestart Checks − Standard Model13 mm Full Gasoline Fuel Valve Open valve Engine Prestart Checks − DX Model + −Connect negative − cable last Tools Needed 1/2 Connecting To Weld Output Terminals Stop engine before connecting to weld output terminalsSelecting Weld Cable Sizes 150 ft 200 ft 250 ft OM-4415 − Operating the Welding Generator Controls Standard Models See Section Turn Engine switch to Off Description Of Controls Standard Models See SectionTo Start To Stop Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary Equipment − Maintenance Routine Maintenance Servicing Air Cleaner Precleaner Paper ElementStop engine Standard Model Shown Adjusting Engine Speed Honda-Powered Units Weld/Power Speed AdjustmentIdle Speed Adjustment Stop Engine Close Stop engine. Close fuel valve Adjusting Engine Speed Kohler−Powered UnitsTools Needed − Troubleshooting TroubleshootingGenerator Power Welding Engine Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams Circuit Diagram For Standard Models Circuit Diagram for DX Models Selecting Equipment − Generator Power GuidelinesGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require? Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt Loads Stick Welding Procedure − Stick Welding Smaw Guidelines Striking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Butt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack Welds Troubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Your distributor also gives ServiceSupport To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s

Miller Electric 185 Weld Test, Troubleshooting − Porosity, Troubleshooting − Excessive Spatter

Models: 185 DX 185

13-13. Weld Test

13-14. Troubleshooting − Porosity

Possible Causes

Corrective Actions

13-15. Troubleshooting − Excessive Spatter

OM-4415 Page 48