Welding Wire: Your Guide to Troubleshooting Common Welding Issues

As a welding expert, I can tell you that the process is difficult, and even experienced welders will face struggles throughout the process. The thing is that you have to fix issues on the spot right when something goes wrong. The problem is almost always metal or its relationship to the welding wire or other welding parameters. At Udo. Here at, we know how prop-found and frustrating it is to run into welding problems.

Understanding Common Welding Issues and Their Causes

  • Porosity (Holes in the Weld):
    • Cause2612: Porosity is almost always caused by a contaminant such as oil, rust, or moisture on the base metal or welding wire. This can also result due to improper shielding gas coverage, inadequate gas flow or using incorrect welding wire.
    • Answer: Clean the base metal and the welding wire properly before you start. Check the shielding gas coverage and regulate the gas flow if necessary. Make sure you use the right welding wire for your material and process.
  • Undercut (Groove At the Welded Toes):
    • Root Causes: Undercut usually comes from using too much heat, wrong electrode angle, or improper travel speed.
    • Solution: Decrease heat input, which can be accomplished by reducing current and voltage, adjust the angle of electrodes to control the weld pool and maintain a constant travel speed.
  • Spatter (Metal Droplets on Workpiece):
    • Root Cause: Spatter may occur if: incorrect welding wire is used, welding parameters are set to too high (amperage or voltage) or the work area is dirty.
    • Solution: Select a low-spatter welding wire, set welding parameters as recommended by the manufacturer, and keep your work area tidy.
  • Lack of Fusion: It is nothing but non-joining of metals.
    • Causes: Inadequate heat input, poor joint preparation, incorrect electrode angle or welding wire.
    • Action: Higher heat inputRequire good joint fit-upProper tilt angle of the electrodeCompatible filler wire with base metals
  • Cracking (Weld or Heat-Affected Zone):
    • Causes: The factors that contribute to cracking include high carbon content in the base metal, rapid cooling, poor preheating or post-weld heat treatment, or the wrong type of welding wire.
    • The solution: preheat the base metals to the appropriate temperature to delay the cooling rate, use welding wire that was formulated for the high strength application or crack resistance, and properly PWHT as required.

Additional Tips for Troubleshooting

  • Welding Machine, Cables, And Others:Make Sure Your Welding Machine, Cables, And Other Equipment You Will Be Using Are All In Good Condition. Welding Problems caused by Faulty Equipment
  • Reference Welding Guides and Specifications: Ensure you have followed a welding procedure specification (WPS) and the recommendation of the manufacturer for the particular welding wire being used.
  • Ask For Help: If you cannot figure out a solution, get help from welders with experience or welding engineers. Your Partner in Welding Success

At, our range of top quality welding wire from reputed brands, ensures you have the material you need to tackle all your weld challenges. The experienced K-TIG Technical Support Team is at your disposal to give you the very best advice and support on how to address common welding problems to achieve top results.


Welding problems in MIG welding can be very frustrating, but in this article a MIG, or GMAW, expert tells you everything you need to do to solve these problems quickly. If you can analyze the defects which are caused commonly by different welding methods and follow the best practices, you will definitely increase the quality and effectiveness of your welding processes.

Note: Welders and purchasing departments, looking for high-quality welding wire? Explore our wide selection of top brands and types atกลุ่มลวดเชื่อม. Find the perfect solution for your welding needs today!

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