10-16. 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.

 

 

 

 

10-17. 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.

10-18. 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-2233 Page 38

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Miller Electric Maxstar 200 STR manual Troubleshooting − Incomplete Fusion, Troubleshooting − Lack Of Penetration

Maxstar 200 STR specifications

The Miller Electric Maxstar 200 STR is a versatile and compact welding power source designed for a range of applications, making it an ideal choice for both professional welders and hobbyists. Known for its reliability and exceptional performance, the Maxstar 200 STR is capable of delivering high-quality results in various welding processes, including Stick (SMAW) and TIG (GTAW) welding.

One of the standout features of the Maxstar 200 STR is its inverter technology, which allows for efficient energy use and a lightweight, portable design. Weighing in at just 51 pounds, it is easy to transport, making it perfect for fieldwork or remote projects. The unit operates on both 120V and 240V input power, providing versatility for different environments and applications. This adaptability ensures that welders can work effectively in various settings, whether in a shop or on a construction site.

Another significant characteristic of the Maxstar 200 STR is its precise arc control. The machine offers adjustable AC frequency, allowing users to fine-tune the arc characteristics for different materials and thicknesses. This level of control is particularly beneficial when working with aluminum, as it helps reduce heat input and minimize warping. The Maxstar also features a pulsing function, which can enhance the weld pool control and improve penetration, making it easier to achieve clean and consistent welds.

The Maxstar 200 STR boasts a robust duty cycle of 60% at 200A, ensuring that it can handle demanding jobs without overheating. Additionally, the unit is equipped with an advanced cooling system, which helps maintain optimal performance during extended use. Safety features, including overload protection and an enclosed design that reduces the risk of contamination, further enhance the machine's reliability.

Moreover, the Maxstar 200 STR supports a range of accessories, including a remote foot control, which allows for added flexibility during TIG welding operations. This feature is particularly useful for precise control over the welding current, enabling welders to make adjustments on the fly without having to stop and manually change settings.

In summary, the Miller Electric Maxstar 200 STR stands out in the welding industry for its combination of portability, advanced technology, and high performance. With its inverter design, precise arc control, and robust duty cycle, it is an ideal solution for professionals seeking efficiency and quality in their welding projects, whether they are working on industrial applications or artistic endeavors.