7 Common Welding Issues And Ways To Fix Them

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welding issues

Welding is a vital part of the Australian economy due to its contribution to various sectors such as manufacturing, mining, construction, etc.

Welding involves a lot of science and variables. It ranks high among different industrial processes and therefore, the demand for has significantly increased in last few years.

But, there are a number of factors that can affect a weld. If you are a DIY welder or a professional welder, you would understand what it means.

The thickness and the form of the material are the usual factors that decide the quality of a welding process. The most common types of welding processes used today are:

  • Metal Inert Gas (MIG) Welding
  • Arc Welding
  • Tungsten Inert Gas (TIG) Welding
  • Flux Cored Arc (FCA) Welding

Welding processes have improved over the last few years and the operators now use superior welding equipment and welding supplies in Melbourne. Still many operators miss a few important steps during the welding process.

So, here are a few common problems that can occur while welding process and steps to fix them.

1) Spatter

The common and unwanted side effect that occurs during the MIG Welding process is the creation of spatter. Spatter is basically the accumulation of droplets of molten material near the welding arc. It occurs due to incorrect polarity, too high welding currents and insufficient gas shielding. To avoid the spatter, it is recommended that you decrease the welding current and the arc length.

So, when you are looking for a welder for sale in Perth or Sydney, make sure you check for the correct usage of polarity, the current flow-rate and gas-type.

2) Porosity

Porosity is caused due to the absorption of gases like nitrogen, hydrogen or oxygen in the weld pool, which in-turn gets trapped in the weld metal upon solidification. The common factors causing porosity are the presence of rust, grease and moisture or the presence of air in-between small gaps during welding. To avoid this, when you choose welding equipment in Adelaide, Perth or Sydney, it has to be made using fresh welding consumables or should be re-baked. Also, keeping the plate edges dry and clean can contribute to a better welding process and avoid porosity.

3) Undercut

An undercut usually occurs when the arc voltage is too high or too long. Also, an extremely quick travel speed or an incorrect usage of the electrode can lead to an undercut too. To avoid this, watch the speed of the weld, monitor the weave used and avoid holding the electrode near the vertical plate while you are making a horizontal fillet weld.

4 Deformation

When the welded materials contract during cooling or hardening, deformation occurs. It can occur if the welding process you choose is not suitable for the considered weld or if there are too many thin beads. It can also occur if there is insufficient clamping before the welding. A good solution to this is by welding joints from both the sides and also from the centre using larger electrodes.

5) Cracks

Cracks are major defects found during any construction work. During welding, filling up cracks isn't a simple process because to correct the error, a new weld needs to be formed. Since the process is tedious and time-consuming, it is better to avoid cracks by spending the necessary time in grinding, cleaning and filling the edges of the plates. Before going for welding supplies in Sydney, check to see if the plates are clamped together at the right temperature.

6) Partial Penetration and Fusion

Partial fusion or penetration occurs when the weld is faulty and ceases to fuse on one side of the joint. It occurs when the electrode is consumed and the weld is automatically deposited as the arc consumes the electrode wire or rod. To solve these issues, it is recommended that you use a wider root gap and electrodes with diameter equal to the gap width of the root. Thus, make sure you consider these points and choose a product which has lower travel speed.

7) Inaccurate Wire Delivery

Inaccurate wire delivery results in blusterous sound within the gun cable, which indicates that there is an issue with the wire delivery system. To avoid this ensure correct set-up of the equipment and carry out proper maintenance. At times, welders use the welding tips that turn out to be too large for the application process and thus it results in major welding problems. In order to avoid this, you need to ensure that the tip of the gun functions properly and also, cross -check the size of the wire used.

Get The Best Welding Supplies in Melbourne

Using the best welding equipment that are up-to-date with the technology can make a huge difference in your welding process. At, Lotos Technology Australia, we supply an exclusive range of TIG and MIG welders for sale in Sydney and Melbourne. Our products are highly appreciated by all the clients due to their durability, trouble-free performance and affordable prices. We also offer after sales service and timely deliveries Australia-wide.

Tell Us About Your Welding Requirements?

Be it small or big, we will take care of all your welding requirements. We offer a huge range of welders for your welding projects. You can explore the welders for sale on our website. We offer 12 months free warranty on all of our products including parts and repairs.

Alternatively, you can also call us at 03 5900 5556 to discuss your welding needs. 

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