The most common welding mistakes and how to avoid them

Introduction

The welding process requires precision, experience, and knowledge of standards. Even minor errors can lead to serious problems, from reduced weld quality to threats to structural safety. Below, we present the most common welding errors and how to avoid them.

Error 1 – No melting

• Cause: too low arc temperature, incorrect current parameters or poor edge preparation.

• Consequences: weakening of the joint, risk of cracks and leaks.

• Solution: use of appropriate welding parameters and proper surface preparation.

Mistake 2 – Weld Porosity

• Cause: presence of moisture, contamination or improper gas shielding.

• Consequences: reduction in strength and corrosion resistance.

• Solution: use of dry electrodes, clean materials and appropriate shielding gas.

Mistake 3 – Cracks in the weld

• Cause: excessive stress, too rapid cooling or poor technique.

• Consequences: risk of structural failure.

• Solution: control of the cooling rate, use of preheating and correct welding technique.

Mistake 4 – Excessive spatter

• Cause: too high arc voltage, incorrectly selected shielding gas.

• Consequences: the need for additional processing, lower aesthetics of the joint.

• Solution: optimization of parameters and selection of the appropriate welding mode.

Summary

Eliminating welding errors requires knowledge, practice, and systematic quality control. Professional welding advice helps avoid problems and improves the efficiency of the entire process.