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4 Common Welding Problems and How To Fix Them




One of the most crucial components of a metal fabrication project is welding. If the welding needed to complete a fabrication project isn’t handled properly, it will be difficult to avoid long-term problems. Some business owners insist on handling their own welding needs, but this usually backfires. DIY welding is a bad idea because it will put the structural integrity of a metal fabrication project in jeopardy.


The welding industry in the United States generates over $2 billion a year. Most business owners are willing to spend big money to hire mobile welding professionals. The welding professionals you hire might encounter certain problems. Here are some of the most common welding problems and what is usually done to fix them.


1. Issues Involving Deformation


When welded metals contract during the cooling and hardening phase, deformation can occur. This problem is usually caused by things like:

  • Insufficient clamping

  • Using the wrong welding sequence for the project in question

  • Too many thin beads

One of the best ways to avoid issues involving welding deformation is by welding from the center out. If you start to notice that deformation is occurring, then you might want to change the sequence of your welds or the location of your joint. You also need to make fewer passes during a welding project to avoid deformation.


2. Dealing With Spatter Problems


When using an arc welder, there is always the risk of spatter. This term is used to describe small molten drops produced near a welding arc. In most cases, this problem occurs when a gas metal arc welder is being used. Some of the most common causes of spatter include:

  • Insufficient gas shielding

  • Higher currents

  • Polarity issues

The first thing you need to do when trying to correct spatter issues is to lower the welding arc length and current. You should also try increasing the torch to plate angle to correct spatter problems.


3. Cracks Are Very Common


Small cracks that develop in a new weld will get progressively worse over time. Experienced welders realize that cracks can’t be repaired with filler material alone. The only way to properly address these cracks is by grinding them down and redoing the weld.


The main focus a welder should have is preventing cracks altogether. The best way to accomplish this goal is by taking extra time to grind, fill, clean and deburr the metal before welding it.


4. Brittle Welds


A brittle weld will not hold up. In most cases, a brittle weld is caused by incorrectly sized or bare electrodes. The only way to ensure brittle welds don’t become a problem is by shielding arc electrodes properly. You also need to pass over the weld several times and avoid excessive currents.


An experienced welder will know how to prevent the welding problems mentioned above. This is why paying professionals to help bring your metal fabrication project to life is so important.


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