Troubleshooting − Lack Of Penetration | Miller Electric OM-230

8-11. Troubleshooting − Lack Of Penetration

	Lack Of Penetration − shallow
	fusion between weld metal and
	base metal.
Lack of Penetration	Good Penetration
	S-0638
Possible Causes	Corrective Actions
Improper joint preparation.	Material too thick. Joint preparation and design must provide access to bottom of groove while
	maintaining proper welding wire extension and arc characteristics.

Improper weld technique.

Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

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

Insufficient heat input.

Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

8-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead.

	S-0637

Possible Causes	Corrective Actions

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

Insufficient heat input.

Select higher voltage range and/or adjust wire feed speed.

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.

Use correct gun angle of 0 to 15 degrees.

8-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

S-0640

Possible Causes

Corrective Actions

Excessive heat input.

Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

OM-230 693 Page 42

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Miller Electric OM-230 manual Troubleshooting − Lack Of Penetration, Troubleshooting − Incomplete Fusion

Contents

Description OM-230 693CProcesses File MIG Gmaw From Miller to You Table of Contents − MIG Welding Gmaw Guidelines − Parts ListTypical MIG Process Connections Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burns Welding can cause fire or explosion Fumes and Gases can be hazardousARC Rays can burn eyes and skin Flying Metal or Dirt can injure eyes Falling Unit can cause injury Welding Wire can cause injuryFire or Explosion hazard Moving Parts can cause injury EMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings About Implanted Medical Devices Symboles utilisés UNE Décharge Électrique peut entraîner la mort 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 Risque D’INCENDIE OU D’EXPLO LE Bruit peut endommager l’ouïeLES Bouteilles peuvent exploser si elles sont endommagées LA Chute DE L’APPAREIL peut blesser LES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Information EMF Principales normes de sécuritéEn ce qui concerne les implants médicaux OM-230 693 Symbols And Definitions Specifications Volt-Ampere Curves Welding Power Source Duty Cycle And OverheatingOverheating Connecting To Weld Output Terminals Installing Work Cable And Clamp Connecting Spoolmatic 15A Or 30A Gun Gun End Gun Liner Wire Outlet Guide Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python32 in 2.4 mm Polarity Changeover Label Information Setting Gun Polarity For Wire TypeInstalling Gas Supply 11/16 Installing Wire Spool And Adjusting Hub Tension Positioning Jumper Links 200 230 460 575 Electrical Service GuideInput Voltage 127 206 18 in 457 mm of space for airflow =GND/PE Earth Ground Selecting a Location And Connecting Input PowerL2L1 230 VAC Scale Threading Welding WirePressure Remove gun nozzle and contact tip OM-230 693 Weld Parameters 226 650-B − Operation Controls Run−in Wire Feed Speed Settings JOG ModeTrigger and pull the trigger again momentarily one second Power Up Status Voltmeter And Wire Feed Speed Meter OperationJog Mode Welding Status Timers Set Up Push Motor Torque SUP Or Reset rES Changing Drive Roll and Wire Inlet Guide Routine MaintenanceUnit Overload Assembly open Aligning Drive Rolls and Wire GuideTurn Off power View is from top of drive rolls Troubleshooting Trouble Remedy OM-230 693 − Electrical Diagram 229 485-A − MIG Welding Gmaw Guidelines Typical MIG Process Connections Select Wire Size Recommendation Wire Speed Typical MIG Process Control SettingsWire Size Amperage Range Select Voltage Holding And Positioning Welding Gun Side View Of Gun Angle Short Normal Long Conditions That Affect Weld Bead ShapePush Perpendicular Drag Slow Normal Good Weld Bead Characteristics Poor Weld Bead CharacteristicsGun Movement During Welding Troubleshooting − Excessive Penetration Troubleshooting − Excessive SpatterTroubleshooting − Porosity Possible Causes Corrective Actions Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Burn-Through Troubleshooting − Distortion Troubleshooting − Waviness Of BeadWeld bead Common MIG Shielding Gases Troubleshooting Guide For Semiautomatic Welding EquipmentApplication Welding power source Welding arc not stable Wire slipping in drive rollsReadjust welding parameters Drive rolls if necessary Grooved 056 Drive Roll And Wire Guide Kits087 0.9 mm 204 Your distributor also gives ServiceSupport For assistance in filing or settling claims, contact To locate a Distributor or Service Agency visitMiller Electric Mfg. Co Your distributor and/or equipment manufacturer’s