Quick fault finding - Poor welding condition

Quick fault-finding guide for poor welding quality

11 January 2024 Rob Lee


Feed the wire without welding, is it feeding smoothly with no vibraton or jerking?
Do you have gas flow? (15-20LPM)
Is the contact 􀆟p the correct size for the wire? (0.6, 0.8, 1.0, 1.2mm)
Replace the contact 􀆟p.
Is the correct size of liner fitted to the torch for the wire size?
It the liner the correct length, so there is some mechanical resistance against the 􀆟p when it is screwed in.
Try another welding torch?
Does the work return cable have a good connec􀆟on at the workpiece and into the welding machine, any signs of overhea􀆟ng or discolouraton of the cable, clamp or cable plug?
Is the feed roller set to the correct size for the wire being used?
Is the feed roller the correct profile for wire type, “V”, “U”, Knurled?
It the welding wire rusty or contaminated?
Is the material you are welding clean and shiny new material?
Is the adjustment of the pressure roll correct?
Is the gas mixture correct for welding wire?
Is the welding wire Aluminium, Mild Steel, Flux Cored or Stainless?

Updated on: 11/01/2024