Common Welding Issues and How to Troubleshoot Them

Porosity (Gas Pockets in the Weld)

Symptoms: Tiny holes or cavities in the weld bead that weaken the joint.

Causes:

• Dirty or rusty base metal
• Contaminated shielding gas
• Moisture in the electrode or filler wire

Fixes:

• Thoroughly clean the metal before welding
• Check for leaks in gas lines and ensure proper gas flow
• Store consumables in a dry, temperature-controlled environment

Incomplete Fusion

Symptoms: The weld bead does not fully bond with the base metal, leading to weak joints.

Causes:

• Insufficient heat input
• Fast travel speed
• Incorrect electrode angle

Fixes:

• Increase amperage or voltage settings
• Slow down travel speed slightly
• Adjust your torch or electrode angle to maintain better contact

Cracks

Symptoms: Cracks that appear either during or after welding, often starting at the weld toe or root.

Causes:

• Rapid cooling, especially on thick materials
• Contaminated base metal
• Poor joint design or fit-up

Fixes:

• Preheat thicker materials as needed
• Clean the joint thoroughly before welding
• Design joints that distribute stress more evenly

Undercut

Symptoms: A groove melted into the base metal along the weld toe, which can reduce strength.

Causes:

• Too high amperage
• Poor torch manipulation
• Fast travel speed

Fixes:

• Lower the amperage to appropriate levels
• Maintain a steady hand and consistent electrode angle
• Slow down your travel speed just enough to allow proper filling

Spatter

Symptoms: Small droplets of molten metal that scatter and stick to the work surface.

Causes:

• Excess voltage
• Incorrect wire feed speed
• Poor gas coverage

Fixes:

• Adjust voltage and wire speed settings to recommended levels.
• Inspect and clean the nozzle and contact tip regularly.
• Use anti-spatter sprays or gels for cleaner results.

Machine-Related Troubleshooting Tips

Sometimes the issue isn't with your technique or materials—it's the machine.

Here are a few quick things to check:

• Cables and connections: Loose or frayed wires can cause irregular arc behavior.
• Ground clamps: A poor ground connection can cause arc instability.
• Consumables: Replace worn-out contact tips, nozzles, and liners regularly.
• Wire feed system: Look for tangles, kinks, or inconsistent feeding.

Routine maintenance and inspections go a long way toward preventing downtime.

Material-Specific Troubleshooting

Different base materials come with their unique challenges:

• Carbon Steel: Tends to be more forgiving but needs proper prep to avoid porosity and cracking.
• Stainless Steel: Sensitive to heat input; improper technique can cause warping or discoloration.
• Aluminum: Highly conductive and prone to oxidation—requires clean surfaces and the right filler metal.

Ensure you're using the appropriate shielding gas and filler for the material you're working with, and consider preheating or adjusting travel speed as needed.

When to Call for Help

If you've gone through all the steps and still can't figure out what's wrong, it might be time to reach out for support.

Machine malfunctions, hidden material flaws, or complex joint designs may require the insight of a welding technician or supplier rep.

Welding issues happen, but knowing how to spot and fix them quickly separates good welders from great ones.

Keep your workspace clean, your equipment maintained, and your settings dialed in—and always be ready to adjust based on what you see.

Work With KDAR Company 

Here at KDAR Company, we take seriously our role as a wholesaler of welding equipment, cable ties, and other related products.

Our retailers can trust us to provide dedicated service and industry expertise.

Contact us today to learn more about our offerings or to let our experts help you source the right equipment for your next project!