Running into issues like weak welds, too much spatter, or a stubborn arc? Whether you're a pro or just getting started in your garage, welding problems can be frustrating—and costly.
In this quick guide, we’ll walk through the most common welding issues and how to fix them. Plus, you’ll see how smart welders like SEFASPE can make your welding experience smoother and more reliable.
Poor Weld Penetration
The problem: Your welds look fine on the surface, but they’re not fusing properly with the base metal, making them weak and prone to cracking.
Possible causes:
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The voltage or current is set too low
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Travel speed is too fast
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Incorrect electrode angle or size
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Base metal isn’t properly cleaned
Quick fixes:
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Increase your current and/or voltage settings
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Slow down your travel speed to allow deeper fusion
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Clean the work surface of rust, oil, or paint before welding
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Use the correct electrode and maintain the proper angle
Sefaspe tip:
Smart models like the Sefaspe MIG205 or MMA120 have auto-adjust features that recommend optimal settings based on wire or rod size. This means better penetration without the guesswork.
Excessive Spatter
The problem: You’re finishing up a weld only to find metal particles flying everywhere, making a mess and more cleanup work.
Possible causes:
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Voltage too high
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Incorrect polarity
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Dirty base metal
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The wire feed speed is too fast
Quick fixes:
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Lower the voltage slightly
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Make sure you’re using the right polarity for your process
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Clean the workpiece thoroughly
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Adjust your wire feed speed gradually
Sefaspe tip:
Sefaspe welders use smart wire feed control to maintain a smooth arc and reduce spatter. Plus, the cooling system kicks in automatically to stabilize performance.
Difficulty Striking or Maintaining an Arc
The problem: The arc keeps cutting out, or it’s hard to strike in the first place, slowing you down and frustrating the process.
Possible causes:
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Dirty or oxidized metal
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Electrode is worn or too short
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Settings too low
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Poor ground connection
Quick fixes:
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Replace or trim the electrode
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Increase your amperage slightly
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Clean your work area and ensure good grounding
Sefaspe tip:
Sefaspe welders are beginner-friendly, with Hot Start and Arc Force features (in stick welding mode) to make arc starting smoother and more stable.
Porosity in Welds
The problem: Your weld has small holes or bubbles in it—caused by trapped gas—weakening the overall joint.
Possible causes:
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Contaminants like moisture, oil, or rust
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Improper shielding gas flow (in MIG/TIG)
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Wrong gas type or wind interference
Quick fixes:
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Always clean your metal thoroughly
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Check gas lines for leaks or obstructions
- Shield your weld area from the wind if working outdoors
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Use the right gas (typically 75% Argon/25% CO₂ for MIG)
Sefaspe tip:
The Sefaspe MIG205 offers stable gas delivery and includes a clearly visible LED screen for monitoring settings, helping reduce porosity risks.
Overheating or Shutdowns
The problem: Your machine shuts off mid-weld, or the torch gets unusually hot.
Possible causes:
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Duty cycle exceeded
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Poor ventilation
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Internal thermal overload
Quick fixes:
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Allow the machine to cool down between long welds
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Check the airflow around the welder
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Use a machine that includes automatic overheat protection
Sefaspe tip:
Sefaspe welders feature intelligent cooling and overload protection. When the system detects high temps, it cools automatically—extending your machine's life and keeping you safer.
Welding problems are common—but most of them are fixable with a bit of know-how and the right machine. Investing in a smart, user-friendly welder like a Sefaspe can make a big difference in your welding quality and confidence.
About Sefaspe
Sefaspe is a brand dedicated to providing high-quality welding equipment for DIY enthusiasts, home users, and hobbyists. Known for its innovation and reliability, Sefaspe has become a trusted name in the welding community, earning numerous accolades for its performance and affordability on platforms like Amazon.
For more information, visit www.Sefaspe.com or https://amzn.to/4j5JnzS.
Media Contact
Sefaspe Marketing Team
Email: info@Sefaspe.com