Cored Wire Fault Finding POSSIBLE CAUSE REMEDY
LACK OF FUSION
POSSIBLE CAUSE REMEDY
Current too low Refer to notes on electrode extension
Consumables
POROSITY
Electrode extension too long for Adjust travel speed to suit desired
Welding
Insufficient shielding gas Check recommended flow rate
current being used degree of penetration
Excessive electrode extension Reduced extension . refer notes Incorrect or inconsistent travel speed Refer to welding techniques
Gas Nozzle too short Replace Modify preparation
Torch angel or direction of travel
Plate condition and impurities Remove non-metallic substances Modify preparation
Narrow joint preparation
Equipment fault on gas control Check for leaks and air ingestion
Root face too large
POOR WIRE FEED LACK OF FUSION
Incorrect tip size Check and replace Direction and speed of travel Refer to noteslillustration
Damaged liner or tip Replace Incorrect torch angle Refer to noteslillustration
Incorrect types, size and pressure of Refer equipment manual Incorrect parameters or torch Check against recommended values for
feed rolls Check tension and slacken if necessary manipulation the wire in question and notes on torch
Spool brake too tight Remove obstruction or replace manipulation
Blocked liner EXCESSIVE SPATTER
SLAG INCLUSIONS Dirty plate Clean plate-wire brush or grinding
Voltage too high for amperage being Check against recommended values
Incorrect welder technique Refer to notes
used
Direction of travel Refer to recommended technique
Shielding gas pressure too high Check against recommended flow rates
UNDERCUT Poor current pick-up Check size or replace worn contact tip.
Travel speed too fast Reduced travel speed or check
parameters
Incorrect torch angle Refer to notes on torch angels
Voltage too high Reduce voltage
ANGLE ‘V’ JOINT - 60O Included Angle ‘V’ FILLET WELD
WEIGHT
PLATE ROOT THEORETICAL Weld
WELD FILLET THEORETICAL WELD WEIGHT WELD
THK GAP VOLUME cm3/m METAUm
SIZE mm VOLUME cm3/m METAUm kg/m
Mm mm mm kg/m
L T L T
4 1 13 12.5 0.1
2 6.0 0.05
5 1 19.5 19 0.15
3 4.5 12.5 0.036 0.10
6 1 27 25.5 0.2 4 8.0 21.0 0.064 0.16
7 1.5 39 38 0.3 6 18.0 42.0 0.142 0.33
8 1.5 49 46.5 0.37 8 32.0 73.0 0.252 0.58
9 1.5 60.5 56 0.44 10 50.0 114.0 0.394 0.89
10 2 77.5 72 0.57 12 72.0 162.0 0.567 1.27
11 2 92 83.5 0.66 15 112.0 248.0 0.887 1.85
18 162.0 1.277
12 2 107 97.5 0.77
20 200.0 1.576
14 2 141 130 1.02
25 312.5 2463
15 2 160 146 1.15
16 2 180 157 1.23 The figures above are for accurate weld volumes of
18 2 223 204 1.6 exact dimensions. In practice it is difficult to obtain mitre
20 2 271 247 1.94 shaped fillet welds, actual welds are generally convex in
25 2 411 375 2.94 profile and an allowance of approximately 15% should
be made when calculating consumable requirements.
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