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1: No arc
Possible Reason Suggested Remedy
Incomplete welding circuit Check earth lead is connected. Check all cable connections.
Wrong mode selected Check the MMA selector switch is selected
No power supply Check that the machine is switched on and has a power supply
2: Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Reason Suggested Remedy
Arc length too long Shorten the arc length
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Damp electrodes Use only dry electrodes
3: Excessive Spatter
Possible Reason Suggested Remedy
Amperage too high Decrease the amperage or choose a larger electrode
Arc length too long Shorten the arc length
3: Weld sits on top, lack of fusion
Possible Reason Suggested Remedy
 Increase the amperage or choose a larger electrode
Work piece dirty, contaminated or
moisture
Remove moisture and materials like paint, grease, oil, and dirt, including mill scale from
base metal
Poor welding technique Use the correct welding technique or seek assistance for the correct technique
4: Lack of penetration
Possible Reason Suggested Remedy
 Increase the amperage or choose a larger electrode
Poor welding technique Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation -

5: Excessive penetration - burn through
Possible Reason Suggested Remedy
Excessive heat input Reduce the amperage or use a smaller electrode
Incorrect travel speed Try increasing the weld travl speed
6: Uneven weld appearance
Possible Reason Suggested Remedy
Unsteady hand, wavering hand Use two hands where possible to steady up, practise your technique
7: Distortion − movement of base metal during welding
Possible Reason Suggested Remedy
Excessive heat input Reduce the amperage or use a smaller electrode
Poor welding technique Use the correct welding technique or seek assistance for the correct technique
Poor joint preparation and or joint
design
-

7: Electrode welds with different or unusual arc characteristic
Possible Reason Suggested Remedy
Incorrect polarity Change the polarity, check the electrode manufacturer for correct polarity
The following chart addresses some of the common problems of MMA welding. In all cases of equipment malfunction,

MMA (Stick) WELDING TROUBLE SHOOTING
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