Weld Diagnosis. Chicago Electric MIG 200 93804, 93804, MIG 200

EXCESS OR BURN-THROUGH

Weld droops on top and underneath, or falls through entirely, making a hole.

WELD DIAGNOSIS

WELD PENETRATION

PROPER

Weld is visible underneath and bulges slightly on top.

INADEQUATE

Weld does not contact the joint fully, just on the surface.

CROSS SECTIONS

POSSIBLE CAUSES AND SOLUTIONS

1. Excessive material at weld:

Reduce wire feed speed.

2. Overheating:

Increase welding speed and ensure that welding speed is kept steady.

WELD NOT ADHERING PROPERLY

Gaps present between weld and previous bead or between weld and workpiece. See areas below.

CROSS

SECTION

POSSIBLE CAUSES AND SOLUTIONS

1. Workpieces too thick/close:

Joint design must allow weld to reach bottom of groove and allow proper welding procedures.

2. Incorrect welding technique:

Maintain

1

/

2

” or less stickout.

Keep arc on leading edge of weld puddle.

Hold gun at proper angles as stated under

Holding The Torch on page 20.

3. Insufficient weld material:

Increase wire feed speed.

4. Insufficient weld heat:

Reduce Welding Speed.

POSSIBLE CAUSES AND SOLUTIONS

1. Dirty workpiece:

Make certain that workpiece is clean and free from oil, coatings, and other residues.

2. Insufficient weld material:

Increase wire feed speed.

3. Incorrect welding technique:

Place stringer bead at correct place in joint.

Adjust workpiece position or weld angle to permit proper welding at bottom of workpiece.

Pause briefly at sides when using a weave bead.

Keep arc on leading edge of weld puddle.

Hold gun at proper angles as stated under

Holding The Torch on page 20.

CROSS

SECTION

BEND AT JOINT

POSSIBLE CAUSES AND SOLUTIONS

1. Improper clamping:

Make sure that pieces are clamped securely in place.

Make tack welds to help hold pieces.

2. Excessive heat:

Weld a small portion and allow to cool before proceeding.

Reduce wire feed speed.

Increase weld speed.

SKU 93804

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

Page 23

POROSITY

Small cavities or holes in the bead.

CROOKED/WAVY BEAD

TOP

VIEW

TOP

VIEW

POSSIBLE CAUSES AND SOLUTIONS

1. Stickout too long:

Reduce stickout.

2. Dirty workpiece or welding wire:

Make certain that workpiece and wire are both clean and free from oil, coatings, and other residues.

3. Insufficient gas flow at weld:

Increase flow of shielding gas.

4. Dirty nozzle:

Clean nozzle by following the directions in the cleaning section of this manual.

5. Wrong type of shielding gas:

Use only the correct welding gas for the application and wire.

POSSIBLE CAUSES AND SOLUTIONS

1. Stickout too long:

Reduce stickout.

2. Inaccurate welding:

Use two hands or rest hand on steady surface.

EXCESSIVE SPATTER

Spatter that is grainy and large.

Fine spatter is normal.

TOP

VIEW

STRIKE TEST

A test weld on a PIECE OF SCRAP can be tested by using the following procedure.

WEAR ANSI GOGGLES DURING THIS PROCEDURE.

1. After two scraps have been welded together and the weld has cooled, clamp one

scrap* in a sturdy vise.

2. Stay clear from underneath while you strike the opposite scrap with a heavy hammer, preferably a dead-blow hammer.

3. A good weld will deform but not break.

A poor weld will be brittle and snap at the weld.

*This test WILL damage the weld it is performed on. This test is ONLY an indicator of weld technique and is not intended to test working welds.

POSSIBLE CAUSES AND SOLUTIONS

1. Wire feeding too fast:

Reduce wire feed speed.

2. Stickout too long:

Reduce stickout.

3. Dirty workpiece or welding wire:

Make certain that workpiece and wire are both clean and free from oil, coatings, and other residues.

4. Insufficient gas flow at weld:

Increase flow of shielding gas.

5. Shielding gas being blown away from weld area:

Protect the weld area from drafts.

SKU 93804

For technical questions, please call 1-800-444-3353;

Troubleshooting section at end of manual.

Page 24