The welding wire has a hard bend

cause

The welding wire will not produce hard bending during production, but will be bumped during handling so that the welding wire of the wire tray falls down, or the scattered wire will be wrapped to the wire tray manually.

Cause phenomenon

The wire with a hard bend will be blocked before entering the gun after entering the wire feed wheel. If it enters the welding torch, it will also be blocked by the wire feeding hose or conductive nozzle, and it can not be welded, and the conductive nozzle will be burned when the welding current and voltage are too large.

Matters needing attention

When unpacking and installing the welding wire, carefully check the welding wire reel to ensure that the welding wire reel is intact and the welding wire is wrapped neatly before use. When transporting the welding wire, be careful to avoid damaging the welding wire tray and causing the welding wire to be scattered. When wrapping the scattered wire back to the welding wire tray, wear gloves to wrap it carefully to avoid hard bending.

                 The welding wire is corroded

cause

The packaging of the welding wire is damaged during transportation, the welding wire storage is too damp, the humidity exceeds the standard, the storage time is too long, and the welding wire is stored after being touched by hand.

Cause phenomenon

When welding, the corroded welding wire enters the wire feeder, the pressing wheel will slip, affecting the normal wire feeding. When the welding wire with corroded parts enters the welding gun, due to the increase in the diameter of the welding wire, it will be blocked by the conductive nozzle and cannot be welded. When the current is too large, the conductive nozzle will be burned, and the weld will be poorly formed and there is debris on the surface.

Matters needing attention

When opening the packaging of the welding wire, check whether the welding wire is rusty, and the rusty welding wire should be replaced in time to the welding wire library. The welding wire packaging shall not be damaged, the humidity of the welding wire library shall be controlled, the welding wire shall be stored 300mm away from the ground and the wall, so that the welding wire purchased first is used first, and the welding wire used is strictly prohibited to touch with hands.

The welding wire has uneven thickness or burrs

cause

When producing welding wire, it is caused by unqualified wire drawing equipment.

Cause phenomenon

During welding, when the welding wire with uneven thickness or burr enters the welding gun wire feed hose, it will have friction with the flexible tube wall and vibration. When the vibration gradually approaches the welding gun, the wire feed will be unstable, interrupted welding or stuck into the conductive nozzle.

Matters needing attention

If intermittent welding occurs after replacing the new conductive nozzle, check the welding wire before welding with a matching conductive nozzle. When it is found that the welding wire without the pressing wheel of the welding machine is not smooth through the conductive nozzle matching the model, it must be the diameter of the welding wire is not uniform, and the welding wire should be replaced.

Improper use of wire feed pressing wheel

cause

When the wire feeding machine is used, the pressing wheel should be matched with the welding wire, the solid core carbon steel welding wire uses a steel wheel, the flux-cored welding wire uses a ceramic wheel, and the wheel groove model matches the diameter of the welding wire. The pressure shall be adjusted according to the requirements of use, and shall not be too loose or too tight.

Cause phenomenon

When the carbon steel solid core welding wire uses the ceramic wheel, it will cause the ceramic wheel to wear too fast. When the flux-cored wire uses a steel wire feed wheel, the flux-cored wire will be crushed and cracked, and the flux will leak out and cannot be welded. When the diameter of the carbon steel solid wire is larger than the diameter of the groove of the wire feed wheel, it is easy to produce indentation on the wire, so that the circular section of the wire is deformed, and the welding wire with indentation will be stuck through the conductive nozzle. When the diameter of the wire is less than the diameter of the groove of the wire feed wheel, the friction between the wire feed wheel and the wire is insufficient, and the wire can not be fed normally. When the wire feed wheel and the diameter of the welding wire match, the wire feed machine pressing wheel pressure should also be appropriate. When the pressure of wire feed wheel is too large, the welding wire will be deformed. When the pressure of the wire feed wheel is too small, the friction between the wire feed wheel and the welding wire is too small, and the wire feed instability will occur when the welding wire is resisted in the wire feed hose or the conductive mouth.

Matters needing attention

According to the requirements of the use of steel or ceramic wire feed wheel, wire feed wheel groove type and diameter to match the wire, wire feed wheel pressure to be moderate, wire feed wheel groove to be cleaned frequently.

            The bending of the welding gun is too large and too fast

cause

Welding is too random or special weld space position makes the welding gun bend too much.

Cause phenomenon

It will cause the welding wire to be blocked too much when running in the wire feed hose of the welding gun, resulting in wire difficulty and wire feeding instability.

Matters needing attention

During welding, the welding gun should be kept as straight or as bent as possible to reduce the running resistance of the welding wire in the wire feeding hose.

           Grooves are ground in the welding gun wire feed spring hose

cause

The use time of the welding gun wire feed spring hose is too long. When the welding wire passes through the wire feed hose, the inside of the hose will be worn out.

Cause phenomenon

During welding, when the welding wire enters the groove in the wire feed spring hose, the change of the bending degree of the welding gun will cause the phenomenon of wire clamping in the groove, which will hinder the normal operation of the wire feed.

Matters needing attention

When the wire feed spring hose is used for too long, the wire is not smooth, and the wire feed hose after the welding torch hand tremors or the wire blocking phenomenon occurs with the change of the Angle of the welding torch, the wire feed spring hose should be replaced in time. Try to keep a large bending Angle of the welding gun to reduce the friction of the welding wire in the wire feeding hose. The wire feed spring hose is too short in the welding gun, which will cause the welding wire to bend inside the welding gun, forming a poor wire feed. When the spring hose is too long inside the welding gun, it will bend, which will increase the friction resistance of the wire feed and cause the instability of the wire feed.

       The conductive nozzle is not cleaned in time

cause

When the welding specification is not properly adjusted, or the welding gun is too close to the welding pool, the welding splash sticks to the conductive mouth, and the longer the welding time, the more the adhesive splash.

Cause phenomenon

The more splashing of the nozzle, the easier it is to block the wire hole of the nozzle, thereby increasing the resistance of wire feeding, resulting in unblocked welding wire or blocked wire phenomenon.

Matters needing attention

Adjust the Angle of the torch and the stretch length of the wire as required during welding to reduce spatter. Often use the needle-nose pliers to clean up the spatters on the conductive mouth. After cleaning up, extend the welding wire out of the conductive mouth 10~15cm long, bend the welding wire from the base of the conductive mouth with the needle-nose pliers, rotate it clockwise or counterclockwise 3~5 turns, and quickly loosen it. Use the power of the welding wire rotation to smooth the wire feed hole of the conductive mouth.

        The wire feed hole of the conductive nozzle is too worn

cause

In the welding process, the conductive nozzle after a long time of welding wire wear will cause the wire feed hole too large.

Cause phenomenon

The large feeding hole of the conductive nozzle will cause poor electrical conductivity during welding, and the discharge between the welding wire and the conductive nozzle will make the wire feed unstable or stick to the conductive nozzle, and the welding wire will swing back and forth in the welding pool, affecting the weld formation.

Matters needing attention

When welding, it is found that the welding wire swings back after the conductive nozzle, and is accompanied by adhesion to the conductive nozzle, and a new conductive nozzle should be replaced in time. The conductive nozzle of the welding gun should be matched with the diameter of the welding wire, and the diameter of the conductive nozzle is too small, resulting in excessive friction resistance, so that the welding wire is not smooth or blocked. Too large conductive nozzle will cause the welding wire to swing back and forth in the weld pool, resulting in poor weld formation.

            Voltage and current do not match during welding

cause

Not adjusted according to the specified welding specifications, lack of welding experience.

Cause phenomenon

When the current is too large and the voltage is too small, intermittent unstable welding will occur, welding spatter is too large, and the sound of the welding wire transition to the weld pool is loud and chaotic. When the current is too small and the voltage is too large, the welding dust is too large, the transition sound of the welding wire to the melt pool is small, and the welding wire and the conductive nozzle are melted and stuck together at the same time, and can not be welded.

Matters needing attention

According to the production needs, adjust according to the welding specification, so that the welding wire into the melt pool in time, the welding wire to the melt pool transition sound uniform.

In addition to the above nine reasons, there may also be poor quality of the welding machine, unstable operation of the wire feed motor, the copper plating layer of the welding wire is not tightly combined, and copper powder is dropped, causing the conductive nozzle to be blocked, forming an unstable wire feed. The fixed shaft of the wire tray of the wire feeder is too loose, and too tight will cause the wire resistance to be too large and the wire is unstable. During welding, the loose ground wire or the contact rust is not cleaned, resulting in excessive resistance and unstable arc will affect wire feeding. The conductive nozzle is not tightened, resulting in unstable welding current and voltage and also unstable wire feeding.

The above experience can provide the judgment basis and solution for the instability of wire feeding in the operation of CO2 gas shielded welding, so as to improve production and product quality.

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