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9 Most Common Welding Mistakes And Tips How To Avoid Them

Almost all industries and sectors make use of welding to a certain extent. And when employing techniques or methods of welding Hanover PA, it’s important to avoid committing mistakes — because a seemingly small one can leave a huge impact on the overall output or final product. Plus, it can also lead to costly repairs.

In this article, we’re tackling nine common welding mistakes and how to avoid them.

Poor preparation. Before starting any welding process, thorough preparation is needed — and this includes cleaning the material to be welded, removing any rust, paint, dirt and surface contaminants, and grinding out cracks. If these are not done, it will result in a weakened weld.

Improper machine setup. Experts in welding Hanover PA should also set up their machine properly in order to avoid poor welding performance. In this step, welding parameters should be set correctly and the appropriate welding technique should be chosen properly. Failing to do so can cause other mistakes like incomplete fusion and joint penetration among others.

Use of worn-out metal. The pre-welding inspection also includes assessing if the metal to be welded is not too worn-out. If a metal has been weakened or has been broken more than once (especially in or near the same place), it needs to be reinforced first. Welding the worn-out metal as is won’t be able to solve the problem.

Improper electrode and wire selection. Many welding processes require the selection of right electrodes and wires because each one is suited for different applications. If one is used in place of the appropriate one, it will only produce poor welding results.

Surface porosity. This refers to the trapping of gas in the weld, forming a cavity when the weld and significantly reducing its strength. This can be prevented by properly handling filler metals and electrodes, ensuring any shielding glass that will be used isn’t contaminated, and properly employing welding techniques.

Incomplete fusion. This occurs when the metal to be welded doesn’t fully merge with the base material. Apart from reducing weld strength, this can also cause corrosion. This can be spotted through visual inspection and doing a fingernail check. For this to be avoided, appropriate welding techniques and welding parameters should be used.

Incomplete joint penetration. This happens when the weld does not fully extend in the entirety of the joint being welded. As a result, a sharp geometry can be created between the weld and unfused base material, acting as a stress concentrator. Tools like mirrors, borescopes, and magnifiers are needed to spot this one.

Arc strikes. Another common mistake in welding Hanover PA are arc strikes, or the marks found on the structures being welded outside of the weld zone. These are created by the accidental rapid discharge of an electrical arc. Arc strikes form brittle microstructure that can be easily cracked and reduce weld strength. Proper grounding and welding technique should be observed to prevent this mistake.

Lack of preventive maintenance. All welders should be responsible for proactively inspecting and maintaining their welding equipment and machine. Maintenance should be routinely done during breaks in the welding operation.

At KLK Welding, we provide a complete line of welding Hanover PA services for home and business owners. Contact us today and let’s discuss the project you have in mind.

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