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38
1: Excessive Spatter
Possible Reason Suggested Remedy
Wire feed speed set too high Select lower wire feed speed
Voltage too high Select a lower voltage setting
Wrong polarity set select the correct polarity for the wire being used - see machine setup guide
Stick out too long Bring the torch closer to the work
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated mig wire Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc


Check the gas is connected, check hoses, gas valve and torch are not restricted. Set

Protect the welding zone from wind and drafts
2: Porosity - small cavities or holes resulting from gas pockets in weld metal.
Possible Reason Suggested Remedy
Wrong gas Check that the correct gas is being used


Check the gas is connected, check hoses, gas valve and torch are not restricted. Set the

Protect the welding zone from wind and drafts
Moisture on the base metal Remove all moisture from base metal before welding
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Contaminated mig wire Use clean dry rust free wire. Do not lubricate the wire with oil, grease etc
Gas nozzle clogged with spatter,
worn or out of shape
Clean or replace the gas nozzle
Missing or damaged gas diffuser Replace the gas diffuser
Mig torch euro connect o-ring miss-
ing or damaged
check and replace the o-ring
4: Wire stubbing during welding
Possible Reason Suggested Remedy
Holding the torch too far away Bring the torch closer to the work and maintain stick out of 5-10mm
Welding voltage set too low Increase the voltage
Wire Speed set too high Decrease the wire feed speed
5: Lack of Fusion − failure of weld metal to fuse completely with base metal or a proceeding weld bead.
Possible Reason Suggested Remedy
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal
Not enough heat input Select a higher voltage range and /or adjust the wire speed to suit
Improper welding technique Keep the arc at the leading edge of the weld pool.
Gun angle to work should be between 5 & 15°
Direct the arc at the weld joint
Adjust work angle or widen groove to access bottom during welding
Momentarily hold arc on side walls if using weaving technique
5: Excessive Penetration − weld metal melting through base metal
Possible Reason Suggested Remedy
Too much heat Select a lower voltage range and /or adjust the wire speed to suit
Increase travel speed
6: Lack of Penetration − shallow fusion between weld metal and base metal
Poor in incorrect joint preparation Material too thick. Joint preparation and design needs to allow access to bottom of
groove while maintaining proper welding wire extension and arc characteristics
Keep the arc at the leading edge of the weld pool and maintain the gun angle at
5 & 15° keeping the stick out between 5-10mm
Not enough heat input Select a higher voltage range and /or adjust the wire speed to suit
Reduce travel speed
Contaminated base metal Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
The following chart addresses some of the common problems of MIG welding. In all cases of equipment malfunction, the manu-

MIG WELDING TROUBLE SHOOTING
Page 39
Instructions Manual for R AZORWE LD 175 DC (K019D)
23/06/2017
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