While MIG welding has a broad range of applications, the learning curve is steep. So if you’re new to this technique, you might have encountered some challenges. However, in many cases, these are caused by issues with your welding machine or equipment. To learn more about the most common MIG welding problems and why they occur, review the list below.

3 Common MIG Welder Issues

1. Lack of Shielding Gas Coverage

MIG welding requires the use of a shielding gas, which is continuously fed from an external source. This both stabilizes the electric arc and blocks air flow from disrupting the weld. However, if your shielding gas isn’t being pumped out fast enough, it may not fulfill these roles, creating a porous weld.

This may be caused by a malfunctioning flow meter. In addition, if you don’t have a flow meter specifically designed to measure carbon dioxide, it might not be capable of reading correctly at all. Shielding gas issues may also be caused by a windy welding location or loose gas fittings.

2. Tangled Welding Wire

Problems may also arise as the welding wire moves through the wire feeder inside your MIG gun. One of the most common issues is referred to as “birdnesting.” This usually begins when the liner is cut too short, or if it’s not the right diameter.

As the wire moves through the feeder, it can get stuck, tangling around itself like a nest. Unfortunately, this issue won’t be uncovered until you remove and replace the liner on your MIG gun.

3. Warped Weld Bead

To produce the perfect weld, your welding machine needs to use extreme heat, and the temperature should increase based on the thickness of the workpiece. If it’s running too cold, your weld bead might look distorted, like an extruding lens. This is because the heat isn’t strong enough to slice through the metal all the way.

You’ll need to consult your welding machine’s manual to find the right temperature point. It’s also important to listen to the sound of your electric arc—if it’s hissing, the voltage may be too high. 

If you still have questions about your specific welding issues, reach out to Aero Services of Fairbanks, AK. Their factory-trained technicians can inspect your welding machine and perform quality repairs, so you can get back to climbing that learning curve. In fact, they’ve been working on this equipment since 1957, and they’re known as the go-to part replacement center for power tools. To learn more about their offerings, visit the website, or call (907) 479-6666 to schedule a welding machine repair today.