10 Welding Issues and How to Fix Them

Excel Steel 860 854 3054 424 Berlin St, East Berlin, CT 06023 miscellaneous metals (1)

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Welding, a critical process in various industrial sectors, plays a vital role in the construction, automotive, and manufacturing industries. The quality of welding significantly impacts the durability and safety of structures and products. 

However, even experienced welders face challenges in the metal fabrication process that can compromise the integrity of their work. Identifying and resolving these challenges is essential for maintaining the highest standards of quality and safety in welding practices.

The presence of weld issues not only hampers the strength and aesthetics of the final product but also can lead to costly repairs and downtime. Recognizing common weld issues and understanding how to address them effectively ensures seamless operations and prolongs the lifespan of welded metals. 

Issue #1: Porosity

Porosity in welding refers to the presence of tiny holes or voids within the weld metal, which can significantly weaken the structure. This issue often arises due to contaminants such as oil, dirt, or moisture on the welding surface or in the fresh welding consumables. Additionally, problems with shielding gas – either an incorrect mixture or inadequate flow from the gas nozzle – can lead to porosity.

To combat this, it is crucial to thoroughly clean the welding surfaces and materials before starting. Also, regularly checking and adjusting the gas flow and composition helps maintain an optimal welding environment, thus reducing the risk of porosity.

Issue #2: Lack of Fusion

Lack of fusion is a common weld issue where the weld metal does not properly fuse with the base metal, resulting in weak joints. This problem often occurs due to insufficient heat input, which prevents the molten weld pool from melting the base metal adequately. It can also be caused by improper welding technique, such as an incorrect torch to plate angle or speed of the welding torch.

To fix this, it’s important to ensure the heat is high enough to create a proper weld pool that fully fuses with the base material. Adjusting the welding parameters such as voltage and current, and using the right technique, such as the correct travel speed and angle, can significantly improve fusion.

Issue #3: Cracking

Cracking is one of the most severe weld issues, as it can significantly compromise the structural integrity of the welded component. Cracks can occur for various reasons, including stress concentrations in the weld area, rapid cooling (which leads to brittleness), or using incompatible materials.

To prevent cracking, it’s crucial to understand the material properties, such as its thermal expansion coefficient and brittleness. Using preheat techniques can reduce the thermal gradients and slow down the cooling rate, thus reducing the tendency for cracking. Selecting filler materials that match or complement the base material’s properties can help minimize the risk of cracking.

Issue #4: Undercutting

Undercutting is a condition where the weld metal erodes away the base metal at the edges of the weld, leaving a groove and creating a weak point. This issue is often caused by excessive heat input, which can be due to high amperage or voltage settings, or by a fast travel speed that doesn’t allow the molten pool to properly fill in the groove.

Adjusting the welding parameters to ensure a balanced heat input can prevent undercutting. Additionally, using the correct angle and direction of the welding torch helps to distribute the weld pool evenly, avoiding excessive concentration of heat at the edges.

Issue #5: Spatter

Spatter consists of droplets of molten metal that are expelled from the welding area, creating a messy and potentially weak weld. This problem is commonly caused by an incorrect amperage setting, which can be either too high or too low, or by using inappropriate shielding gas.

Adjusting the welding machine settings to a suitable level for the material and thickness can reduce spatter. Additionally, ensuring that the shielding gas mixture and flow rate are optimal for the welding process is important. For instance, using a higher percentage of CO2 in MIG welding can increase spatter, while adding more argon can reduce it.

Issue #6: Distortion

Distortion in welding occurs when the heat from the welding process causes the metal to expand and contract unevenly, leading to warping or bending of the material. This is particularly problematic in thin materials or large structures used in steel fabrication. 

To minimize distortion, it is important to use proper clamping techniques to hold the workpieces in place during welding. Additionally, employing a welding sequence that evenly distributes heat can prevent excessive localized expansion. For example, using backstepping or welding in short segments alternating between different parts of the workpiece can help control distortion.

Issue #7: Incomplete Penetration

Incomplete penetration happens when the weld does not extend through the full thickness of the joint, resulting in a weak connection. This is often due to insufficient heat input, incorrect welding angle, or too fast a travel speed.

Adjusting the welding machine to provide adequate heat and slowing down the travel speed can help ensure full penetration. Additionally, the correct angle and proper welding technique, such as slightly weaving the torch, can aid in achieving deeper penetration into the joint.

Issue #8: Overlap

Overlap occurs when the weld metal extends over the top of the base material without properly fusing with it, resulting in a weak joint. This issue often arises from excessive deposition of weld metal, which can be due to incorrect weld settings such as high amperage or a slow travel speed. 

Adjusting these settings to ensure a controlled and appropriate flow of weld metal is key to preventing overlap. Additionally, the welder’s technique, including the angle and movement of the torch, plays a significant role in preventing excess build-up of material. Proper preparation of the weld joint, such as ensuring the right fit-up and gap, is also important in preventing overlap.

Issue #9: Slag Inclusions

Slag inclusions are non-metallic particles that become trapped in the weld, often leading to weak spots or defects. This problem is common in welding processes that use flux, such as stick welding or flux-cored arc welding. 

To prevent slag inclusions, it is crucial to ensure complete slag removal between passes and after the final pass. Using the right technique to chip away and brush off the slag is essential. Additionally, maintaining the correct arc length helps ensure that the slag is properly melted and floats to the surface of the weld pool, where it can be easily removed.

Issue #10: Electrode Problems

Electrode problems in welding can lead to a range of weld issues, including poor arc stability, spatter, and weak welds. Using an incorrect type or size of electrode for the specific welding application is a common mistake among steel fabricators. 

For instance, using an electrode that is too large can lead to excessive heat input and difficulties in controlling the weld pool. Conversely, an electrode that is too small may not provide enough heat for proper penetration. 

Selecting the right electrode based on the material type, thickness, and welding position is crucial. Also, ensuring the electrode is not damaged or contaminated is important for achieving a stable arc and high-quality weld.

Proper storage and handling of electrodes, especially for flux-cored or shielded metal arc welding, are crucial to prevent moisture absorption and subsequent weld defects. Additionally, using the correct amperage setting for each electrode type and regularly adjusting welding machine settings according to electrode specifications are essential for optimal weld quality.


Understanding these issues is crucial for welders to produce strong, reliable, and aesthetically pleasing welds in applications like horizontal fillet weld. Addressing these weld issues not only ensures the structural integrity of the welded components but also enhances the efficiency and cost-effectiveness of welding operations.

With the right knowledge, techniques, and equipment, welders can effectively tackle these challenges, contributing to the advancement of welding practices in various industries. 

If you’re looking for top-notch welding solutions and expert advice, look no further than Excel Steel. Our team of experienced professionals and high-quality welding supplies can help you achieve the best results in all your welding endeavors. 

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