Common Welding Mistakes and How to Avoid Them

The welding process is a crucial stage in the construction and metal manufacturing world. The quality of the weld determines the strength and durability of the overall structure.
However, many workers unknowingly make mistakes while welding, resulting in weak, cracked, or uneven joints.

Here are some common welding mistakes and how to avoid them to ensure your work remains strong and precise.

1. Choosing the Wrong Welding Wire
The most common mistake is using the wrong type of welding wire for the metal material. For example, using wire designed for carbon steel on stainless steel will result in a poor bonding and prone to corrosion.

How to avoid this:

• Ensure the type of welding wire is suitable for the material being used.
• Also, pay attention to the wire diameter and the thickness of the material being welded.

2. Inappropriate Welding Current (Amperes)
Too high a current can cause the metal to overheat, while too low a current can result in an imperfect bond.

How to avoid this:

• Adjust the amperage to the wire type and metal thickness.
• Follow the welding wire manufacturer's instructions (usually printed on the packaging).

3. Incorrect Electrode Angle and Distance
The electrode position significantly affects the shape and strength of the weld. If the angle is too slanted or the distance is too far, the weld can be uneven and produce excessive spatter.

How to avoid this:

• Maintain the electrode angle at around 15–30 degrees from the metal surface.
• Maintain an arc length of around 2–3 mm to maintain a stable heat flow.

4. Lack of Metal Surface Cleanliness
Metal that is still dirty with rust, oil, or paint will prevent complete fusion between the base metal and the welding wire. This will result in porosity (fine holes) in the weld.

How to avoid this:

• Clean the area to be welded using a grinder, sandpaper, or wire brush.
• Ensure the surface is completely dry and free of oil before starting welding.

5. Unsteady Hand Movement
Unconsistent hand movement results in an uneven molten metal bead and a weak joint.

How to avoid:

• Use small, slow zigzag or semicircular motions.
• Practice a rhythmic motion to ensure even heat distribution throughout the joint.

6. Not Using Personal Protective Equipment (PPE)
Besides affecting work results, welding without PPE poses a significant safety risk. UV rays from the welding arc can cause skin and eye irritation (welder's flash).

How to avoid:

• Wear an automatic welding helmet, leather gloves, long, heat-resistant clothing, and safety shoes at all times.

Conclusion
Good welding results depend not only on the equipment, but also on the operator's technique and accuracy. By selecting the right welding wire, adjusting the current correctly, and maintaining cleanliness and consistency, the quality of the joint will be much stronger and neater.

PT Intisumber Bajasakti (ISBS) provides a variety of high-quality welding wires that meet SNI standards for construction, fabrication, and industrial needs.
We are ready to support every project with the best products and professional service.

📞 Phone: 021-66675999
🌐 Website: intisumberbajasakti.com
✉️ Email: info@intisumberbajasakti.com

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