Learn how to diagnose and resolve 8 common welding problems—spatter, porosity, undercut, and more—with step-by-step solutions. Whether you’re a beginner or a seasoned welder, these practical tips will help you improve weld quality, save time, and avoid costly rework. Perfect for anyone using Sefaspe welders or other MIG, Stick, or TIG machines.
Every Welder Faces Problems
Even the most experienced welders run into trouble: spatter everywhere, tiny holes (porosity) weakening a weld, or cracks ruining a perfect joint. For beginners, these issues can be frustrating—you might spend hours grinding spatter or redoing welds. For pros, downtime eats into profits and delays projects.
The truth is, most welding problems have simple fixes—if you know how to read the signs. Spatter isn’t just “part of welding”; it’s a signal that your settings or prep are off. Porosity usually means moisture, contamination, or poor gas flow. By learning to identify root causes, you can solve problems in minutes instead of hours.
In this Sefaspe welding troubleshooting guide, we’ll cover the 8 most common welding problems, what causes them, and how to fix them fast—whether you’re running MIG, Stick, or TIG on mild steel, stainless, or aluminum.
Spatter: Tiny Metal Droplets Ruining Your Weld
The Issue: Those tiny molten metal drops that stick all over your workpiece—not only messy but time-consuming to clean.
Causes:
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Incorrect voltage or wire feed speed
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Dirty or oily metal surfaces
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Wrong shielding gas (like pure CO₂)
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Worn contact tip
Fix It:
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Adjust your settings—use synergic control on Sefaspe MIG welders to auto-match voltage and wire feed speed.
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Clean the metal thoroughly (2 inches around the joint).
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Use a 75/25 Argon/CO₂ mix for mild steel or pure Argon for stainless.
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Replace worn contact tips.
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Use anti-spatter spray for easier cleanup.
Porosity: Tiny Holes in the Weld
The Issue: Bubble-like holes that weaken weld strength and look terrible.
Causes:
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Moisture or damp electrodes (especially E7018)
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Contaminated filler wire
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Insufficient shielding gas or leaks
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Dirty weld surface
Fix It:
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Keep electrodes and wire dry (Sefaspe welders perform best with clean, dry consumables).
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Set MIG gas flow to 20–25 CFH and check for hose leaks.
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Use wind screens outdoors to protect the gas shield.
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Always clean the joint before welding.
Undercut: Grooves Along the Weld Edge
The Issue: Grooves that reduce weld strength and look like poor penetration.
Causes:
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Too much voltage or travel speed
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Long arc length
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Wrong torch angle
Fix It:
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Lower the voltage slightly.
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Slow down and keep a short, steady arc.
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Hold the torch at a 10–15° angle.
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If an undercut appears, make a second pass to fill it.
Lack of Penetration: Weak Welds That Fail Under Stress
The Issue: Weld doesn’t fully fuse with the base metal—dangerous for load-bearing joints.
Causes:
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Low amperage or voltage
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Fast travel speed
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Poor joint prep or too-small electrode
Fix It:
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Increase heat or voltage for deeper fusion.
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Slow down your travel speed.
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Bevel thick materials and leave a slight gap.
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Use proper wire size (e.g., 0.035" for thicker metal).
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For best results, use multi-pass welding with Sefaspe MIG machines.
Overheating and Warping: Metal Distorts During Welding
The Issue: Heat causes the metal to bend or twist, especially thin steel.
Causes:
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Uneven heat input
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High amperage
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Large weld beads
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No clamping
Fix It:
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Weld in sequence to balance heat.
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Use lower heat settings.
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Make multiple small beads instead of one large one.
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Clamp the workpiece securely.
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Heat-straighten if distortion occurs.
Cracked Welds: Dangerous and Costly
The Issue: Cracks that compromise safety and strength.
Causes:
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Moisture (hydrogen embrittlement)
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Incorrect filler metal
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High stress or fast cooling
Fix It:
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Use low-hydrogen electrodes (like E7018).
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Match filler to base metal.
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Preheat thick or high-carbon steel.
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Allow the weld to cool slowly under a welding blanket.
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Grind out cracks completely and re-weld.
Arc Blow: Unstable Arc Wandering Around
The Issue: Arc wanders away from the joint, making control difficult.
Causes:
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Magnetic interference
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Improper ground clamp placement
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Uneven current flow
Fix It:
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Move the ground clamp closer to the weld (within 6 inches).
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Twist cables together to reduce magnetic fields.
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Adjust your welding direction.
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Lower amperage to stabilize the arc.
Poor Weld Appearance: Bumpy or Uneven Beads
The Issue: Strong welds that just look bad—uneven, wobbly, or rough.
Causes:
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Inconsistent travel speed or arc length
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Unsteady hand
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Dirty filler metal
Fix It:
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Maintain consistent movement and arc length.
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Adjust the wire feed for smoother beads.
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Use clean wire or electrodes.
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For cosmetic welds, grind and polish for a pro finish.
Troubleshooting Is a Skill
Welding troubleshooting isn’t luck—it’s understanding how heat, metal, and your Sefaspe welder work together. Spatter often means dirty metal; porosity means moisture or poor shielding. Once you recognize these signs, you can solve problems fast and prevent them next time.
Every issue is a learning opportunity. The more you weld, the faster you’ll master your technique and adapt your machine for different materials. Keep this Sefaspe welding troubleshooting guide nearby—your go-to reference for cleaner, stronger, and more professional welds every time.
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.
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