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Cause:
Turbulence caused by too high a rate of shielding gas flow rate
Remedy:
Reduce shielding gas flow rate, recommended:
shielding gas flow rate (l/min) = wire diameter (mm) x 10
(e.g. 16 l/min for 1.6 mm wire electrode)
Cause:
Too large a distance between the torch and the workpiece.
Remedy:
Reduce the distance between the torch and the workpiece(recommended: 10-15 mm)
Cause:
Tilt angle of the welding torch is too great
Remedy:
Reduce the tilt angle of the welding torch
Cause:
Wirefeed components have incorrect diameter
Remedy:
Use wirefeed components with correct diameter
Poor wirefeed
Cause:
The braking force has been set too high
Remedy:
Reduce the braking force
Cause:
Hole in the contact tube is displaced
Remedy:
Replace the contact tube
Cause:
Faulty inner liner in welding torch
Remedy:
Check the inner liner for kinks, dirt, etc.
Cause:
The wirefeed rollers are not suitable for the wire electrode being used
Remedy:
Use suitable wirefeed rollers
Cause:
Wirefeed rollers have the wrong contact pressure
Remedy:
Optimise the contact pressure
Cause:
The wirefeed rollers are soiled or damaged
Remedy:
Clean the wirefeed rollers or exchange them for new ones
Cause:
Inner liner wrongly laid or kinked
Remedy:
Replace inner liner
Cause:
Inner liner or wire inlet nozzle wrongly dimensioned
Remedy:
Ensure inner liner or wire inlet nozzle are correctly dimensioned
Cause:
Inner liner was kinked while being inserted
Remedy:
When inserting the inner liner, only handle it around the infeed tube
Cause:
The inner liner has been cut too short
Remedy:
Replace the inner liner and cut it to the correct length
Cause:
After being cut to length, the inner liner is too short
Remedy:
Exchange the inner liner and shorten it to the correct length
Cause:
Wire electrode worn due to excessive contact pressure at the wirefeed rollers
Remedy:
Reduce the contact pressure on the wirefeed rollers
Cause:
Wire electrode contains impurities/corroded
Remedy:
Use high-quality wire electrode with no impurities
The welding torch becomes very hot
Cause:
The welding torch has been operated beyond its maximum number of amps
Remedy:
Reduce welding power or use a higher capacity torch
Cause:
The design dimensions of the welding torch are not sufficient for this task
Remedy:
Observe the duty cycle and loading limits
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