5 Common Welding Problems and How to Address Them

Date Posted:2 January 2023

Welding is a complex process that requires a variety of tools and techniques to achieve a successful outcome. However, there are many different issues that can arise from welding. And, without using the correct technique and procedures, welding can turn out poorly, with potentially hazardous consequences. Improper welding can create weak spots, incorrect joint configurations, and even cause sparks that can cause fires or explosions.

Today, we want to tackle a couple of welding problems that you may face, along with how to address them:

1. Spatters

In welding, spatter is a problem that happens when small droplets of molten material are created near the welding arc. This usually happens when the welding current is too high, the polarity of the connection is incorrect, or the shielding gas is not enough.

To avoid spatter, the welding current should be lowered, the arc length reduced, the angle between the torch and the plate increased, the polarity and gas type checked, and the gas nozzle cleaned.

2. Undercuts

An undercut is a welding issue that can happen when the voltage of the arc is too high, the arc is too long, the wrong electrode is being used, the angle is incorrect, the electrode is too large for the material, or the travel speed is too quick.

To prevent an undercut from happening, the welder should pay attention to the speed of the weld, monitor the amount of weave used, and avoid placing the electrode near the vertical plate when performing a horizontal fillet weld. Additionally, it is important to use an electrode that is the proper size for the material so that molten metal does not accumulate.

3. Deformations

Deformation of welded metals can occur when the metal cools and hardens after being welded.

To prevent deformation, it is important to use a large electrode and to clamp the metal firmly before welding. Welding from both sides of the joint and from the centre out in opposite directions can also help. If deformation begins to occur, it can be prevented by changing the location of the weld and the sequence of the welds, as well as by making fewer passes during welding.

4. Porosity

Porosity is an imperfection in a weld that is caused by trapped gases such as nitrogen, oxygen, and hydrogen. This can be caused by moisture, rust, grease, paint, or air in the weld area or due to improper gas shielding or welding on a small gap.

To avoid porosity, clean and dry the plate edges, check the welding torch for leaks, and make sure the correct torch angle is used, as well as clean the gas nozzle of the welding device.

5. Cracks

Cracks can be a major issue when it comes to welding, as they can worsen over time. Unfortunately, fixing this problem is not as easy as just filling the crack with the material. Instead, the crack has to be ground out, and a new weld needs to be done in order to produce a good result.

The best way to fix this problem is through prevention. A welder should take the time to properly grind, clean, and file the edges of the metal plates so that they fit together easily. Heating both sides of the joint is necessary, and the metallurgist should be sure to check the temperature before welding. Additionally, the welding machine's settings need to be tested to make sure the proper amount of heat is being used.

Conclusion

All in all, prevention is better than cure, so preparing for a good weld is a must to ensure the welding job is done without a single issue! But of course, problems happen from time to time, and when they do, it is vital to know how you can address the problem to ensure the welding job doesn't have any integrity issues and looks good.

National Welding and Industrial Supplies is a leading welding equipment supplier, offering high-quality tools and equipment to meet any welding needs. Check out what we offer today!

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