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Cored Wire Trouble-Shooting Guide


Consistently good welds throughout a wide range of welding conditions are easily obtained when the variables that affect the flux cored process are understood and controlled. Each variable listed below is important in obtaining a balanced welding condition.

  • Welding Voltage
  • Welding Current
  • Welding Travel Rate
  • Welding Gun Angle
  • Contact Tip to Work Distance

When any of these variables is out of adjustment, certain problems may arise. To obtain the best results in correcting these problems, the following suggestions are made:

1. Electrode stubs on work.

a. Voltage too low.

b. Wire feed too fast.

c. Poor ground.

2. Arc burns back to contact tip.

a. Voltage too high.

b. Wire feed speed too low.

c. Loose or worn feed rolls.

d. Kinked or clogged welding conduit.

3. Rough arc or heavy spatter.

a. Improper volt or amps.

b. Loose or worn contact tip.

c. Arc blow.

d. Gun pointing in wrong direction or too much angle in relation to the weld.

e. Nozzle too far from the work.

4. Erratic wire feed.

a. Worn or loose contact tip.

b. Worn feed rolls.

c. Clogged welding conduit.

d. Fluctuation of line voltage.

e. Faulty relay or contactor in control.

5. Weld bead is not uniform.

a. Wrong volt/amperage setting.

b. Inconsistent travel speed.

c. Operator varying nozzle to work distance.

Posted in Filler Metals , Tagged with Cored Wire