Arc Weld Troubleshooting

Arc welding is a complex process that requires precision and attention to detail. Even the most experienced welders encounter issues from time to time. Fortunately, many of these issues are easily resolved with proper troubleshooting techniques. In this guide, we’ll outline some common arc weld issues and provide tips on how to resolve them.

Weld Spatter

One of the most common issues welders encounter is weld spatter, which is the metal debris that splatters out of the weld during the process. Weld spatter can be caused by a variety of factors, including:

To resolve weld spatter, try adjusting the wire feed speed, amperage, and gas flow. Clean the metal surface before welding to remove any contaminants that may cause spatter. Make sure to hold the gun at the correct angle and distance from the workpiece to prevent spatter.


Porosity is another common welding issue that results in small holes in the weld. This issue is often caused by improper gas coverage or contamination on the surface of the metal. To resolve porosity issues, make sure that the gas flow is adequate, and that the metal surface is clean and free from any contaminants.


Burn-through occurs when the weld is too hot, and the metal burns through. This issue is often caused by using too much amperage or by welding too slowly. To prevent burn-through, adjust the amperage and welding speed to ensure that the metal doesn’t get too hot. You can also use a lower amperage setting or a thicker metal piece to avoid this issue.


Undercutting occurs when the metal at the edge of the weld is melted away, creating a groove in the metal. This issue is often caused by incorrect welding techniques, such as holding the gun at the wrong angle or not maintaining a consistent speed. To prevent undercutting, make sure to hold the gun at the correct angle and maintain a consistent speed throughout the weld.


These are some of the most common arc weld issues that welders encounter. By understanding the causes and solutions to these issues, you can improve your welding skills and produce high-quality welds every time.

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