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Cellulose Coated Deep Penetration Electrodes For Pipe Welding

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Low Heat Input Welding Alloys

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Dc Welding Rectifiers

Welding Cables

CAUSES AND CURES AND COMMON WELDING TROUBLES

» POROUS WELDS

REASON WHY IT HAPPENS
1. Excessively long or short arc length. 2. Welding current too high. 3. Insufficient or damp shielding gas 4. Too fast travel speed 5. Base metal surface covered with oil, grease, moisture, rust, mill scale etc. 6. Wet, unclean or damaged electrode

SOLUTION
1. Maintain proper arc length
2. Use proper welding current
3. Increase Gas Flow-rate & check gas purity
4. Reduce travel speed
5. Properly clean base metal prior to welding
6. Properly maintain and store electrodes

» CRACKED WELDS

REASON WHY IT HAPPENS
1. Insufficient weld size 2. Excessive joint restraint 3. Poor joint design and/or preparation 4. Fillet metal does not match base metal 5. Rapid cooling rate 6. Base metal surface covered with oil, grease, moisture, rust, dirt or mill scale.

WHAT TO DO
1. Adjust weld size to part thickness
2. Reduced joint restraint through proper design
3. Select the proper joint design
4. Use more ductile filler
5. Reduce cooling rate through preheat
6. Properly clean base metal prior to welding

» UNDERCUTTING

REASON WHY IT HAPPENS
1. Faulty electrode manipulation 2. Welding current too high 3. Too long an arc length 4. Too fast travel speed 5. Arc blow

WHAT TO DO
1. Pause at each side of the weld bead when using a weaving technique
2. User proper electrode angles
3. Use proper welding current for electrode size and welding position
4. Reduce arc length
5. Reduce travel speed
6. Reduce effects of arc blow

» DISTORTION

REASON WHY IT HAPPENS
1. Improper tack welding and/ or faulty joint preparation 2. Improper bead sequence 3. Improper set-up and fixing 4. Excessive weld size

WHAT TO DO
1. Tack weld parts with allowance for distortion
2. Use proper bead sequencing
3. Tack or clamp part securely
4. Make welds to specified size

» SPATTER

REASON WHY IT HAPPENS
1. Arc blow 2. Welding current too high 3. Too long an arc length 4. Wet, unclean or damaged electrode

WHAT TO DO

1. Attempt to reduce the effect of arc blow
2. Reduce welding current
3. Reduce arc length
4. Properly maintain and store electrodes

» LACK OF FUSION

REASON WHY IT HAPPENS
1. Improper travel speed 2. Welding current too low 3. Faulty joint preparation 4. Too large an electrode diameter 5. Magnetic arc below 6. Wrong electrode angle

WHAT TO DO
1. Reduce travel speed
2. Increase welding current
3. Weld design should allow electrode accessibility to all surfaces within the joint
4. Reduce electrode diameter
5. Reduce effects of magnetic arc blow
6. Use proper electrode angles

» OVERLAPPING

REASON WHY IT HAPPENS
1. Too slow travel speed 2. Incorrect electrode angle 3. Too large an electrode

WHAT TO DO
1. Increase travel speed
2. Use proper electrode angles
3. Use a smaller electrodes size

» POOR PENETRATION

REASON WHY IT HAPPENS
1. Travel speed too fast 2. Welding current too low 3. Poor joint design and/or preparation 4. Electrode diameter too large 5. Wrong type of electrode 6. Excessively long arc length

WHAT TO DO
1. Decrease travel speed
2. Increase welding current
3. Increase root opening or decrease root face
4. Use smaller electrode
5. Use electrode with deeper penetration characteristics
6. Reduce arc length

» MAGNETIC ARC BLOW

REASON WHY IT HAPPENS
1. Unbalanced magnetic field during welding 2. Excessive magnetism in parts of fixture

WHAT TO DO
1. Use alternating current
2. Reduce welding current and arc length
3. Charge the location of the work connection on the workplace

» INCLUSION

REASON WHY IT HAPPENS
1. Incomplete slag removal between passes 2. Erratic travel speed 3. Too wide a weaving motion 4. Too large an electrode 5. Letting slag run ahead of arc 6. Tungsten spitting of sticking

WHAT TO DO
1. Completely remove slag between passes
2. Use a uniform travel speed
3. Reduce width of weaving technique
4. Use a smaller electrode size for better access to joint
5. Increase travel speed or change electrode angle to reduce arc length
6. Properly prepare tungsten and use proper current