Frequent MIG Welding Issues

🔥MIG Troubleshooting Guide

📋 Problem: Porosity

• Is the gas on?
• Is CFH at least 15–20?
• Is the environment too windy?
• Is your material clean (free of rust, oil, paint, etc.)?

🔧 Fix: Ensure proper gas flow, make sure your gas isn't being blown away, clean material.

📋 Problem: Excessive Spatter

• Too high voltage?
• Is arc length too far?
• Ensure correct polarity.

🔧 Fix: Turn down voltage, shorten arc length, verify polarity (DCEP).

📋 Problem: Burn-Through

• Are your settings too hot?
• Is travel speed too slow?

🔧 Fix: Adjust settings lower for thinner material thickness, move steadily and move quicker if needed.

📋 Problem: Lack of Fusion and/or Cold And Buldged Out Bead

• Travel speed too fast?
• Is voltage too low or too low overall heat?
• Arc length correct?

🔧 Fix: Slow travel, increase voltage or overall heat (increase voltage and wire speed), shorten arc length.

📋 Problem: Inconsistant Arc/Popping Sound When Welding

• Check voltage and wire speed balance.
• Is arc length too far?
• Ensure correct polarity.

🔧 Fix: Adjust voltage up or wire speed down, shorten stick-out, verify polarity (DCEP), shorten arc length.

📋 Problem: Undercut

• Voltage too high?
• Improper gun angle?
• Travel speed too fast?

🔧 Fix: Turn down voltage or overall heat (decrease voltage and wire speed), try pointing gun more towards the side of the joint that is undercutting to help fill, slow down travel speed to let puddle have time to fill out joint.