Though Arc Welding is one of the more popular welding methods these days, there are still some issues that can arise from performing it if you are not aware of these potential issues. That being said, let’s talk a bit about these issues and what you can do to resolve them. We will start by discussing length faults and how they can affect your weld job.
First of all, arc welding must be a constant process (no breaks in the progression of the weld), and the arc length will have a significant effect on the voltage. If you were to reduce the overall length of the arc, the voltage would decrease, and this would ultimately serve to reduce the level of heat in the weld. In addition to that, increasing the arc length would increase the voltage, which could lead to some rather serious issues.
Consequences of Length Fault
Too Short: With undersized arc you will typically run into a weld bead that is fragmented or uneven. It will remain intact but will not be acceptable by any stretch of the imagination.
Too Long: A longer arc length will present different heights throughout the bead and may even break in places. This will be entirely too weak and it will not hold together under stress. If you are working on an industrial project, it could very well present a danger for those working around it.
If the arc length is perfect, then the profile will be consistent and there will be virtually no spatter. This will hold together under stress and create a more acceptable scenario whether you are working on a simple home project or welding for a large company. In any case, you will want to make sure that the weld you create is decent for the sake of safety and project integrity.
Moving your rod quickly during an arc welding session can result in a number of different issues. If you move at the proper speed you will find that the bead is consistent and it holds quite nicely. Other conditions however can create a rather serious problem.
Too Fast: If you are welding too fast, then you will have a thin bead that would be much weaker and unable to hold together.
Too Slow: This will create a larger weld where the majority of the pool has collapsed into the crack. This might not be considered weak, but it will be unsightly, and certainly not something that you want to see on your welding project.
The need to increase the arc voltage should be relatively obvious, but some beginner welders still need a helping hand in this area. Let’s take a look at a few of the issues that can result from lowering or even raising your voltage:
Low Arc Voltage: This issue can result in ropy weld beads, and the weld will be difficult to start in general.
High Arc Voltage: This will not only appear sloppy, but your weld bead will also be fat. There will be no consistency and it all honesty it will look more like a metallic slug than anything else. In addition to that it will spatter, and removing the slag will be extremely difficult.
As you could probably guess, the right voltage will result in a decent weld bead that you can consider to be safe. That being said, it is important to check your settings and ensure that you are utilizing the proper welding method before you start a project.