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impede the delivery of shielding gas. To rectif y this obstacle, the welder needs to look at the nozzle opening bef ore starting a weld. T his double-check might prevent weld spatter f rom f alling into the weld. 5. T he weld nozzle is held too far away f rom the weld puddle. T he volume of shielding gas reaching the weld is diminished, and dilution of the shielding gas with the atmosphere severely af f ects the weld. 6. T he GMAW gun is laid at an angle that will spread the gas f low out and actually suck in the atmosphere f rom the back side, opposite the nozzle direction. A 5- to 15-degree angle, perpendicular to the joint, is an acceptable angle f or f orehand or backhand methods with GMAW or FCAW guns and SMAW electrodes. 7. Paint, grease, oil, glue, and sweat release large volumes of gas when exposed to arc welding temperatures. T his is especially true with solid-wire GMAW and gas tungsten arc welding (GTAW), but FCAW and SMAW processes are vulnerable as well. T he f lux makeup was not designed to handle such contamination. 8. When mill scale and rust are welded over, decomposition gases are f ormed, and oxidation begins, which can involve the presence of moisture. T he strong possibility of cold lapping and lack of f usion at the weld toe also exists. When a metal oxidizes, it is no longer truly a metal and cant be expected to respond to welding the same as a metal, especially when welding f lux is not used. 9. Plating compounds with zinc, such as in the galvanization process, can create a problem. Z inc melts at approximately 420 degrees F. At welding temperatures f ar in excess of 2,000 degrees F, zinc changes f rom a solid to a gas in a f raction of a second. Also, zinc dust is a byproduct of the welding process. T he release of both gases and dust make welding galvanized metal an unpleasant experience. (In an ef f ort to prevent letters and calls of protest, let me say electrodes and welding procedures have been developed to weld galvanized material successf ully. However, training and lots of practice are absolutely necessary to overcome the presence of all that trapped gas.) 10. SMAW electrodes, FCAW electrodes, and submerged arc welding (SAW) flux absorb moisture in an unprotected environment. To address moisture in the welding process, codes are pretty clear about the use of dryers and ovens to store these materials. SAW f lux in particular is like a sponge. Once the container is opened, the welder should store the package according to the manuf acturers directions. 11. T he gas flow is too high. Gas f low of 50 to 60 cubic f eet per hour (CFH) at the GMAW nozzle and 20 to 30 CFH at the GTAW torch should be plenty. If not, ask why. Wide-open gas f low at the nozzle actually creates turbulence and can pull outside air into the weld zone. Additionally, its a terrible waste of gas and adds unnecessary cost to the project. T he only exception might be if the shielding gas contains more than 50 percent helium. 12. A pinched or smashed gas hose doesnt deliver the shielding gas properly. If the gas hose is more than 20 f t. long, the possibility of it kinking is pretty good. 13. Improper use of antispatter compounds, sprays, or gels can be a major contributor to porosity. When used in excess, the antispatter material becomes a contaminant, boiling into a gas when exposed to the high temperatures of the welding arc. Also, jamming the GMAW gun into a container of antispatter gel can result in the gel dripping back into the weld puddle. An operator should use the anti- spatter material properly or not at all. 14. Weld filler metals contaminated with paint, grease, oil, tape, and glue can release gases when exposed to the very hot welding arc. Even dirty gloves used during GTAW can contaminate the consumables. Cleaning solid wire and f lux-cored wire with wire wipes and GTAW f illers with steel wool is a good idea. 15. Contaminated GMAW gun liners can introduce unwanted elements to the weld pool. All the grease, oil, dust, and dirt f ound in the shop environment collects on the wire and ends up in the guns whip liner. Stainless steel and high-nickel-alloy wires are especially susceptible to attracting these contaminants.
16. GMAW right on the edge of an outside corner joint might create problems given the awkward position of the nozzle. T he nozzle of ten does not cover the joint properly, causes turbulence, and draws in outside air into the weld joint. 17. If the weld joint is open at the root, it will suck in air f rom the back side. Unprotected liquid metal can absorb air easily. 18. T he welding gas itself could be contaminated. If the welding gas is a suspect, the shop needs the gas supplier to certif y that the gas has the correct dew point. 19. A contaminated gas hose could be a culprit, in particular, hoses that have been used f or other activities prior to being used in a welding application. In one real-world example, a hose was grabbed f rom a storeroom to repair a cut hose that was attached to the wire f eeder. Unf ortunately, a bug had built a nest in the hose while it was sitting undisturbed in the storeroom. In another example, an air hose that was previously used as an air line f or a tool on a line with an oil lube system on it was quickly connected to welding equipment only to f ind out later that the hose was f ull of air tool oil. 20. Damaged O-ring seals on the GMAW gun whip where it plugs into the wire f eeder or the GTAW torch cap where it screws into the torch could introduce unwanted air into the welding process. 21. Cut or burnt hose anywhere f rom the regulator f lowmeter to the connection at the f eeder could create issues. 22. A defective gas solenoid at the wire f eeder or the GTAW machine is a possible contributor to conditions that create porosity.