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Problem Solving

Expulsion at Weld Interface

  • Short Squeeze Time
  • Low Weld Force
  • Dirty – Scaly Material
  • Poor Fit Up
  • Insufficient Edge Distance

Surface Expulsion/Electrode Sticking

  • Short Squeeze Time
  • Long Weld Time
  • Short Hold Time
  • Low Weld Force
  • High Weld Current
  • Dirty - Scaly Material

Electrode Mushrooming

  • Insufficient Cooling
  • Low weld Force
  • High Weld Current
  • Small Electrode Face Area
  • Long Weld Time
  • Welder Head Impacts Work

Low Weld Strength

  • Short Weld Time
  • Low Weld Force
  • Low Weld Current
  • Small Electrode Face Area
  • Poor Heat Balance
  • Welds Too Close Together

Excessive Weld Indentation

  • Long Weld Time
  • High Weld Force
  • High Weld Current
  • Poor Fit Up
  • Welder Head Impacts Work

Internal Cracks in Weld Nugget

  • Short Hold Time
  • Low Weld Force
  • Dirty- Scaly Material
  • Metallurgy of Material Welded
  • Poor Head Follow Up

Displaced Weld Nugget

  • Electrode Misalignment
  • Poor Heat Balance
  • Poor Fit UP

Cracks in Parent Material

  • High Weld Force
  • Insufficient Cooling
  • Metallurgy of Material Welded

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