PROBLEMS > SOLUTIONS                                           .
The following are a variety of typical problems with MIG/WIRE welding, and the solution to fix the issue.

PROBLEM: Base Metal Spatter

SOLUTION: Grinding the spatter is an effective traditional solution, but is expensive, time consuming, and fatiguing. The easiest, most-effective solution is the use of anti-spatters. There are two types: Solvent-based and water-based. Solvent-based are the easiest to use, though water-based are more effective where the application is particularly sensitive to over-spraying, or there are environmental concerns.

PROBLEM: Porosity or Pitting in Weld

SOLUTION: Clean the base metal. Use an anti-spatter on the base metal and nozzle spray or dips on the nozzle to maximize gas coverage. Use ‘pads’ to clean rust, scale, and dirt from the wire, and lubricate for best feeding and to reduce burnbacks.

PROBLEM: Spatter on Nozzle

SOLUTION: Remove spatter with proper tools, and treat the nozzle with the proper product.

PROBLEM: Poor Wire Feed

SOLUTION: Can be caused by dirty, rusty, and low-quality wire that has poor cast and helix. Use a liquid lubrication for smoother and cleaner feed.

PROBLEM: Burnbacks

SOLUTION: To prevent wire adhering itself to the tip or wire that won’t feed properly by using cleaner and lube pads to remove the dirt and dust from the wire.

PROBLEM: Aluminum Welding

SOLUTION: Use a high-quality cleaner ‘pad’ and anti-spatter protection for the best results.

PROBLEM: Short Liner, Tip, Nozzle Life

SOLUTION: First, check the wire quality. Then check for dirt, rust, and particulate matter in the environment—these will damage liners and create drag. Use wire pads to clean and lubricate (this can increase tip and liner life up to 50%). Use proper nozzle tools to maintain nozzle shape. Keep nozzles free from spatter with a gel, dip, or spray.

PROBLEM: Spatter on Fixtures

SOLUTION: Protect with an anti-spatter aerosol, lightly coating the surfaces to be protected.

PROBLEM: Dirty, Dusty Wire

SOLUTION: Use wire pads and lubricants. This removes unwanted draw compounds and residues accumulated on the wire in the manufacturing process.

PROBLEM: Welding Stainless Steel

SOLUTION: Use a high-quality cleaner ‘pad’ and apply a high-quality anti-spatter protection for the best results.