Troubleshooting − Excessive Spatter | Miller Electric OM-230

8-8.	Troubleshooting − Excessive Spatter
		Excessive Spatter − scattering of molten metal particles that
		cool to solid form near weld bead.
		S-0636
	Possible Causes	Corrective Actions
Wire feed speed too high.		Select lower wire feed speed.
Voltage too high.		Select lower voltage range.
Electrode extension (stickout) too long.		Use shorter electrode extension (stickout).
Workpiece dirty.		Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.		Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.		Use clean, dry welding wire.
		Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
8-9.	Troubleshooting − Porosity
		Porosity − small cavities or holes resulting from gas pockets
		in weld metal.
		S-0635
	Possible Causes	Corrective Actions
Insufficient shielding gas at welding arc.		Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
		Remove spatter from gun nozzle.
		Check gas hoses for leaks.
		Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
		Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.		Use welding grade shielding gas; change to different gas.
Dirty welding wire.		Use clean, dry welding wire.
		Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.		Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
		Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.		Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

8-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

Excessive Penetration Good Penetration

S-0639

Possible Causes	Corrective Actions

Excessive heat input.	Select lower voltage range and reduce wire feed speed.

	Increase travel speed.

OM-230 693 Page 41

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Miller Electric OM-230 Troubleshooting − Excessive Spatter, Troubleshooting − Porosity, Possible Causes Corrective Actions

Contents

Processes OM-230 693CDescription File MIG Gmaw From Miller to You Table of Contents − Parts List − MIG Welding Gmaw GuidelinesTypical MIG Process Connections Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burns ARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyes Fire or Explosion hazard Welding Wire can cause injuryFalling Unit can cause injury Moving Parts can cause injury California Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical Devices UNE Décharge Électrique peut entraîner la mort Symboles utilisés 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 LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesser Proposition californienne 65 Avertissements LES Fils DE Soudage peuvent provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécurité Information EMFEn ce qui concerne les implants médicaux OM-230 693 Specifications Symbols And Definitions Welding Power Source Duty Cycle And Overheating Volt-Ampere CurvesOverheating Installing Work Cable And Clamp Connecting To Weld Output Terminals Connecting Spoolmatic 15A Or 30A Gun Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python Gun End Gun Liner Wire Outlet Guide32 in 2.4 mm Installing Gas Supply Setting Gun Polarity For Wire TypePolarity Changeover Label Information 11/16 Positioning Jumper Links Installing Wire Spool And Adjusting Hub Tension Input Voltage Electrical Service Guide200 230 460 575 127 206 Selecting a Location And Connecting Input Power 18 in 457 mm of space for airflow =GND/PE Earth GroundL2L1 230 VAC Pressure Threading Welding WireScale Remove gun nozzle and contact tip OM-230 693 Weld Parameters 226 650-B Controls − Operation JOG Mode Run−in Wire Feed Speed SettingsTrigger and pull the trigger again momentarily one second Jog Mode Voltmeter And Wire Feed Speed Meter OperationPower Up Status Welding Status Timers Set Up Push Motor Torque SUP Or Reset rES Routine Maintenance Changing Drive Roll and Wire Inlet GuideUnit Overload Turn Off power Aligning Drive Rolls and Wire GuideAssembly open View is from top of drive rolls Troubleshooting Trouble Remedy OM-230 693 − Electrical Diagram 229 485-A Typical MIG Process Connections − MIG Welding Gmaw Guidelines Wire Size Amperage Range Typical MIG Process Control SettingsSelect Wire Size Recommendation Wire Speed Select Voltage Side View Of Gun Angle Holding And Positioning Welding Gun Push Perpendicular Drag Conditions That Affect Weld Bead ShapeShort Normal Long Slow Normal Poor Weld Bead Characteristics Good Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Porosity Troubleshooting − Excessive SpatterTroubleshooting − Excessive Penetration Possible Causes Corrective Actions Troubleshooting − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Burn-Through Troubleshooting − Waviness Of Bead Troubleshooting − DistortionWeld bead Troubleshooting Guide For Semiautomatic Welding Equipment Common MIG Shielding GasesApplication Readjust welding parameters Welding arc not stable Wire slipping in drive rollsWelding power source Drive rolls if necessary 087 Drive Roll And Wire Guide KitsGrooved 056 0.9 mm 204 Service Your distributor also givesSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s