Troubleshooting Common MIG Welding issues

MIG welding is a popular welding method because it’s equally as effective as it is easy to learn. However, there are common issues that can arise if you haven’t properly prepared your equipment. This guide to troubleshooting common MIG welding issues will help your next weld, and each weld after that yields the high-quality results you’re aiming for.

Porosity

Porosity is a common MIG welding frustration that results from gas getting caught in the metal. These gas pockets can happen both on the surface and within the metal. Not only is this going to make the weld look messy, but it’s also going to compromise its overall strength. The three most common reasons for porosity occurring include insufficient shielding gas coverage,

contaminants (oil, paint, rust, etc.) on the base metal, and extending your welding wire too far out of the nozzle.

If extending the wire too far is the issue, then all you have to do is ensure it never extends more than half an inch out of the nozzle. In the case of contaminants on the base metal, simply clean the base metal with tools such as an angle grinder, sandpaper, wire brush, or acetone.

Insufficient gas coverage will require quite a few inspections; you should ensure that there are no leaks or other forms of damage in the gas hoses or welding gun, the nozzle is the right size, and the gas flow is correct (check your flow meter).

Spatter

If your MIG welding process is producing an excessive amount of spatter, it’s going to hurt both the appearance of the weld and the metal fusion process. Troubleshooting excessive spatter is similar to porosity; insufficient shielding gas coverage, base metal contaminants, and extending the welding wire too far are all causes of spatter.

Furthermore, excessive wire feed speeds and voltage settings can lead to spatter occurring as well. As long as you monitor wire feed speed and voltage levels and make sure they aren’t too fast and high respectively, you can prevent this common issue from hindering your next weld.

Excess or Insufficient Penetration

Excess penetration occurs when your weld metal melts all the way through the base metal. Similar to spatter, this can be the result of your wire feed speed being too fast and your voltage settings being too high, so adjust accordingly. On the other hand, if your wire feed speed or voltage levels are too low, it’s going to weaken the fusion of your metals due to a lack of penetration. By perfecting the wire feed speed and voltage levels, you can provide the weld with the proper heat input it requires to yield high-quality results.

Troubleshooting common MIG welding issues can be stressful, but this guide can hopefully help alleviate some of that stress. Although these are common causes of MIG welding issues, they certainly aren’t the only causes. Researching and understanding topics like the basic principles of choosing MIG welding consumables is essential to ensuring your operation goes smoothly. Without proper care and consideration, you can wind up with a poor weld. However, when you understand the ins and outs of the MIG welding process, you can get the results you need.