Like other welders, MIG welders can also have some problems. When you’re buying a welder, you must have the knowledge of solving the common problems of it. If you don’t have enough knowledge about MIG welder repair, suddenly appeared problems will interfere with your work. This will be a waste of time.

Many times, you have to go to a professional to solve small problems. So that useless money will be spent. And when you know how to fix your welder yourself, it will save your time and money, and also make you much more skillful.

I will discuss MIG welder repair in detail today and give you the right guidelines so that you can fix your welder yourself.

Some Common MIG Welder Problems

Basic Problems

  1. Machine Starting Problem
  2. Machine Fuse Blows
  3. MIG Welding Light Doesn’t Work
  4. Polarity Switch Doesn’t Work
  5. Electrode Holder’s Excess Heats Up
  6. Electrical Shocks
  7. Excess Heat Of Welding Cable
  8. Ground Clamp Turns Bad
  9. Cable Damage

Welding Problems

  1. Inappropriate Wire Feeding
  2. Low Welding
  3. Porosity
  4. Shrinkage Crash On The Weld
  5. Lateral Cracks On The Weld
  6. Excess Spatter

Advanced Welding Problems

  1. Weld Metal Absorbency Or Porosity
  2. Inappropriate weld bead profile
  3. Fusion Shortage
  4. Defective wire Delivery Problem

MIG Welder Troubleshooting

Machine Starting Problem:

Cause:

Because of wrong input voltage, blown up of fuse, having problems in the circuit, or overheating the machine can create a problem for starting.Solution:

Machine Fuse Blows

Cause:

If the machine starts without any problem and suddenly the fuse creates a problem, then there has a defective fuse. This can lead to short circuit. In addition, the other cause may be the wick is so small.Solution:

•Solve the short circuit problem.•Or, change the fuse with a bigger one if the first fuse is too small.

MIG welding light doesn’t work

Cause:

Due to no or low airflow, the machine’s equipment will not start. Then the light also doesn’t work.

Solution:

If The Polarity Switch Doesn’t Work

Cause:

Polarity switch stops working if the switch decrepit or the welder is under load.

Solution:

Electrode Holder’s Excess Heating Up

Cause:

Because of loose connection or having set an irregular duty cycle, the Electrode holder will excessively heat up.

Solution:

Electrical Shocks

Cause:

Electrical shocks may cause if the grounding of the frame is improper.

Solution:

Overheating of welding cable:

Cause:

When the cable is very old and in the defective condition, the cable will heat up very quickly. And also for the improper duty cycle that can happen.

Solution:

Welding Problems

Inappropriate wire feeding

Cause:

When there is inappropriate wire feeding problem, this may create many problems in welding. Worn driver rolls cause inappropriate wire feeding problem.

Solution:

Low welding

Cause:

If the welding gun’s tip worn out, it can cause flat welding.

Solution:

Porosity

Cause:

Due to insufficient gas flow, another common welding defect named porosity occurs.

Solution:

Shrinkage Crash On The Weld

Cause:

When the wire is pale, that can cause shrinkage crash on the weld. Having small follicles in the wire can also cause this problem.

Solution:

Lateral Cracks On The Weld:

Cause:

Because of fast welding speed or high arc voltage or low current lateral cracks on the weld can occur.

Solution:

Excess Spatter:

Cause:

Excess CO2 or improper impedance can cause excess spatter. This is a mass welding defect. This problem may also occur due to high voltage.

Solution:

If you are interested, you can read 10 Best MIG Welder’s Review here.

Advanced Welding Troubles

1. Weld Metal Porosity

Inappropriate Surface conditions:

Cause:

The surface defiling with rust, grease, or oil can cause metal porosity. An open surface can also cause this.

Solution:

Absorbency Problem

Gas Coverage:

Cause:

When your welder’s gas shield is not appropriate, that can cause porosity problem. When this is inappropriate, the gas shield can’t protect the weld puddle adequately. And when shielding gas exchange with the air, the porosity occurs.

Solution:

Mismatching of Base Metal

Cause:

Mismatching of the base metal can make porosity problems also. If the metal you are welding is not the same baking bar material you are using, then porosity can occur.

Solution:

2.Inappropriate Bead Problems

Lacking Input Heat

Cause:

Using improper input power can cause this problem.

Solution:

Fix the input power correctly.

The wrong techniques in welding and using small cable can also cause Bead problem. So, be careful about the welding technique and size of cable.

3. The problem of Fusion Shortage

Cold Lapping:

Cause:

Cold lapping occurs for lacking fusion. The wire contacts with the welding pool and the wire melts.

Solution:

4. Defective wire Delivery Problems

Contact Tips:

Cause:

Because of faulty wire delivery, contact tips can occur. For excess spatter or touching on the welding paddle, contact tips can get obstructed.

Solution:

Inappropriate Size of Gun Liner:

Cause:

Short wire delivery occurs when the size of the gun liner is improper. Extending wire can also create this problem.

Solution:

Worn Out Gun:

Cause:

Wire feeding problem can occur for a worn out gun.

Solution:

Drive Roll:

Cause:

Excessive drive roll pressure can cause problem in wire feeding. If the drive roll is very loose, the wire feeding will stop. And, when the drive is very tight, then it will crash suddenly. So, both the loose and tight drive roll can cause a problem.

Solution:

If you take care of your MIG welder properly, you can use it for a long time without any problem.Always keep your welder clean so that there are no problems. Take precautionary measures before the problem arises; this is the wise thing to do.This is a perfect guide to MIG welder repair. It will help you very much to MIG welding troubleshooting. I guess, now you are more confident in MIG welding machine repair.

Knowing your MIG welder’s problems and solutions to those problems, now save your time, save money, and make yourself more efficient.

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