Common Welding Mistakes – Avoidance and Quality

Common Welding Mistakes – Avoidance and Quality

Introduction to Welding:


Welding is the act of joining together to pieces of metal by heating up the two surfaces with a blowtorch hot enough until they are almost at the point of boiling. To properly combine some pieces the use of hammering comes in handy as well as pressing down. There is a lot to welding, several different kinds of welding and more. With welding you can be doing work, a hobby, or even creating art; the opportunities and possibilities are almost endless and limitless.

However with that being said there is a lot that can go wrong with welding and mainly it is a few simple mistakes that are actually more common than people care to think about. The top five common mistakes associated with welding are all mentioned below.

Top Five Common Welding Mistakes:

  1. Preparing Poorly –

    Make sure you clean the rust on the surface by grinding before you start you the joint will last longer
    Make sure you clean the rust on the surface by grinding before you start you the joint will last longer

    Before you weld metal you need to prep the metal and to properly prep the metal this means to remove any dirt or rust that there may be as well as any paint. And if you see any cracks they need to be filled in to help make it stronger again. Having a crack in the metal makes it weak, even if the crack is a small one. The cracks, if any, should be completely grounded out before any welding is done.

  2. The materials used are thick –

    Common Welding Mistakes – Avoidance and Quality 1
    Consult the chart before you start can help you have a better joint and save time also as electricity alot.

    Mostly all of the materials used in welding are very thick and when it comes to materials such as these there needs to be more than one pass at welding everything to make it welded together correctly let alone strong and reliable. It is better to go over it a few times to be sure that all of the filler metal is bonding to the base metal properly.

  3. The metal can be worn out –

    Welding is known for being able to fix almost everything but there are situations where welding is not even able to help out. Metal can become too weak from being worn out and when metal becomes like this even welding cannot solve the issue. Keep in mind that if there is a place that has broken more than once in the same spot than that area should be reinforced for a better support system.

  4. Selection of wire ones and electrode ones –

    Common Welding Mistakes – Avoidance and Quality 2
    With each kind having the correct wire and the right electrodes and it is important to choose the right one before starting the welding application

    Within the world of welding there are three kinds of welding; there is flux-cored welding, there is MIG welding and then there is stick welding. This is because different electrodes are designed for different applications and or uses.
    If you decide to use something else instead of the right materials than the results of the welding will be very poor. An example is how there are some sticks in which are designed for what is known as DC welding. Another example is how with some flux-cored wires that are self-shielding are able to be used for what is known as multi-pass welding.
    It is also very important to know that there is different polarity settings needed at the source of power for welding that is solid wire versus welding that is flux-cored. You need to also be sure to properly take care of everything because if not rusting may occur with the wiring. For stick welding and all-purpose uses it is best suggested to use 6011, it is the best electrode out there for this use and as for MIG welding and other kinds of all-purpose uses it is best suggested to use .035 S6 wire.

  5. Techniques that are wrong –

    Common Welding Mistakes – Avoidance and Quality 3
    Just like with everything else in life practice makes perfect and it takes time to get the hang of something new.

    This aspect is something that can be simple or something that can be major; consider pushing versus pulling, a gun angle versus an electrode angle, the speed at which it is all traveling at, the length of the arc and much, much more. An example of what you need to keep an eye out for and to avoid is that if the rate of which the traveling is going on is too slow than there will be a ton of extra metal pooled together as a deposit.

Simple Rules To Avoid Welding Mistakes

Welding can be dangerous work. Even if you remain safe, the mistakes you make could end up wasting resources and material, taking up time in the process and adding time as you redo the task. Knowing some of the rules and resolutions to welding can save you a world of trouble.

  1. Weld Porosity – 3 Problem-Points

    a. Impurities on the surface of the metal can lead to this problem. Before welding, a thorough clean-up of the metal will do it good. Oil, water, flux and other impurities need to be absent on the metal’s surface. Aluminum needs an external surface free of oxides before you weld the metal or porosity will certainly occur.

    b. The backing bar material does not match the weld metal. Consequence: porosity. The best rule to follow in this case, namely if you are using a backing bar, is to see that it and the welding metal are of the same type.

    c. Damp electrodes can also lead to porosity. Storing them in a clean dry place is a step in the right direction. It is best not to expose them to air or water before you use them in your welding.

  2. Incomplete Fusion Between Weld Metal & Parent Metals – 2 Problem-Points

    a. If there are gaps between your weld beads or spaces present at the base or root end of a joint, you can expect fusion issues. While performing a welding pass use sufficient weld metal to cover up the space between the previous bead and the one you are currently working on. Place the weld metal at the joint’s very end. Fill up any craters, and you are good to go.

    Common Welding Mistakes – Avoidance and Quality 4
    a nice welding joint after complete

    b. You will observe incomplete fusion if there is not enough weld material deposited at the weld joint to fill it. Keep making welder passes until the weld joint is filled fully with the weld metal. That is all there is to this rule.

Please tell me what is problem you usually have at the first time you start welding ? An what is the best solution for that problem ? I would like to hear from you.