Frequent MIG Welding Issues

Written By Luke Alderfer

🔥MIG Troubleshooting Guide

📋 Problem: Porosity

  • Is the gas on?
  • Is CFH at least 15–20?
  • Is the environment too windy?
  • Is your material clean?
🔧 Fix: Ensure proper gas flow, make sure your gas isn't being blown away, clean base metal.

📋 Problem: Excessive Spatter

  • Too high wire speed.
  • Is arc length too far?
  • Ensure correct polarity.
🔧 Fix: Turn down wire speed, shorten arc length, verify polarity (DCEP).

📋 Problem: Burn-Through

  • Is material too thin for your heat settings?
  • Are you lingering too long in one spot?
  • Is travel speed too slow?
🔧 Fix: Adjust settings lower for thinner material thickness, move steadily and move quicker if needed.

📋 Problem: Lack of Fusion

  • Travel speed too fast?
  • Is voltage too low?
  • Arc length correct?
🔧 Fix: Slow travel, increase voltage, 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.
Luke Alderfer
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Frequent TIG Welding Issues