Troubleshooting & Diagnostics Flashcards

A welder notices excessive spatter during GMAW. Which parameter adjustment is most likely to reduce spatter?

Answer: Decrease voltage to match wire feed speed

Excessive spatter in GMAW is often caused by voltage being too low or too high relative to wire feed speed; matching voltage to wire feed speed stabilizes the arc.

During SMAW, the electrode sticks to the base metal repeatedly. What is the most likely cause?

Answer: Amperage set too low

Electrode sticking in SMAW is most commonly caused by amperage set too low, which cannot sustain a stable arc.

A welder observes undercut along the toes of a fillet weld. Which corrective action is most appropriate?

Answer: Reduce amperage or slow travel speed

Undercut is caused by excessive heat or travel speed that melts the base metal faster than filler can fill; reducing amperage or slowing travel speed corrects this.

During FCAW, the weld bead has a rough, convex profile with poor tie-in to the base metal. What is the most likely cause?

Answer: Voltage too low

Low voltage in FCAW produces a convex, ropy bead with poor fusion because the arc is not wide enough to wet out properly.

A GTAW welder notices tungsten inclusions in the weld. What is the most probable cause?

Answer: Tungsten contacted the weld pool

Tungsten inclusions occur when the tungsten electrode touches the molten weld pool, causing pieces to break off and become embedded.

A welder is making a groove weld and notices lack of fusion on one sidewall. Which is the best corrective action?

Answer: Direct the arc toward the unfused sidewall

Directing the arc toward the unfused sidewall ensures adequate heat penetration and fusion in that area.

During SAW, the weld bead shows a humped or rippled surface with irregular width. Which parameter is most likely misadjusted?

Answer: Travel speed too high

Excessively high travel speed in SAW causes the bead to become narrow and humped because the weld pool cannot spread uniformly.