Maintenance & Repair

Common Welding Problems

Welding Problems

Welding is not an easy process. It has some mistakes and problems even though there is a massive improvement in welding equipment. But it is a fact that welders forget some essential steps while operating with the machines. However, the untrained or beginners cannot recognize the correct welding problems due to the lack of experience and training.

So here we will share some common welding problems that help you in maintaining your welding procedure.

Five common welding problems


Spatter is a common problem in the process of arc or gas welding. The droplets of molten metal have produced and spread around in all the nearest areas. It is too high due to some reason in the welding procedure. If the temperature and current is too high or an inefficient supply of gas, then spattering appears.

However, to reduce the spatter, it is essential to lower the welding current and arc length. The welder also needs to check the welding polarity according to metal pieces.


An undercut is one of the common welding problems. Arc voltage creates the undercut, so it needs to be in the required amount. Incorrect electrode usage and the angle also causes the undercut as the too large or short electrode has penetration problems. So many factors drive the undercut in the welding procedure, including the speed of the electrode or welding machine.

It is essential to use the appropriate size or thickness of the welding electrode to prevent the undercut in the welding procedure. The high amount of molten metal causes the undercut. Moreover, don’t place the electrode too near the metal pieces while making the vertical and horizontal plates.


Porosity in the weld is due to incorporating the nitrogen, oxygen and hydrogen in the molten metal pool. This entrapped material releases during solidification and causes porosity. The main reason for porosity is moisture, rust, paint and gas shielding, and rust on metal pieces.

The welder needs to re-bake or use the new welding torches that prevent that leakage. Moreover, fresh and clean welding plates also help to avoid porosity. Welders must follow preventive measures during the welding process to avoid porosity, as it is not easy to overcome these problems after completing the process.


Deformation is the effect of the welding procedure. It appears during the cooling and hardening of the molten metal if the welding process is not suitable according to the intended weld, then it also creates the tin beads and clamping.

However, to avoid deformation after welding, it is essential to start welding from the centre and move towards the edges. Use the large electrode that creates the clamping firmly and prevents deformation. Moreover, change the welding sequence and the joint location to reduce the risk of problems.


Cracks in welding appear when the arc voltage is high or low. The inappropriate usage of the electrode also creates gaps. The high speed of the electrode also causes the crack.

However, use the appropriate current for the welding machine, suitable electrode, voltage and arc to get the crack-free weld.

Last but not least – one of the often neglected problems is safety. Welding is a dangerous process and injuries are pretty common. Welders have to wear protective gear at all times and we are not talking only about helmets & shields – many injuries are caused by the lack of proper protective jackets for welding, boots or gloves.

Joe Lee
Hi, My name is Joe Lee and I am the founder of My purpose of creating this blog is to spread the knowledge of auto with others.

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