MIG welding is a very efficient option for any welder to make or repair things. Hence, it used widely and gave complications sometimes due to overuse or not applying correctly. If you are learning the MIG welding common thing, you are now facing MIG welder popping. No, that does not mean the machine has staring popping weird things. It’s all about the sound and the weld that it is making.
Why MIG welder popping?
Almost every time, MIG welders are make a slight popping noise when the speed is either too fast or too slow. Frequently adjusting the wire speed will solve the matter. You are just changing the settings gradually until you find the right point. The optimal settings will give you a steady buzzing or sizzling noise.
What should we look for?
When welding with MIG, listen to the sound it made- half of the problem will recognize by that. Also, see that what welding marks its making. But before that, you have to know what it looks and sounds in the standard way.
A MIG welder that is in good condition and adjusted well will sound like frying bacon strips. That nice sizzle makes your morning happy. The MIG will make sizzle like sound with some spits and pops. When you are going to weld with the MIG gun, the finishing product will be relatively even and full. We had been work with some different settings of a MIG welder. In this below description, you will see how a weld penetrated correctly on the surface of metal sheets or objects.
Materials thickness matters
The thickness impacts on the welding performance. When the work piece is in 1/8 inches, you need to run the machine in higher IPM. But for thicker metal sheets, the IPM will be slower. It’s because slower speed will help you to weld deep and penetrate the weld into the layer.
Same as the materials density wire size is important too. There is a difference between a thick wire sizes run speeds with the sheer size wire speed. Such as if a wire is .35, then it will run better at 150 IPM, and a .23 wire is good with 300 IPM.
Wire & Metal Type
Wire type plays a vital toll also in MIG welder popping. Like, solid core wire and flux core wire do not work well at the same speed. Even a stainless steel sheet and aluminum sheet shower different results in the same IPM. See the user manual of your MIG welder to get the right speed with varying types of wire and metal sheets.
Wire-speed amperage also determines the welder popping. If the amperage is not right, it could burn the wire. To get the correct amperage, take the metal thickness, and multiply it with 1000.
For example, if you are welding 1/8 inches aluminum sheet, you will multiply it by its decimal form with 1000. So,
The decimal form of 1/8= .125
The Amperage will be .125*1000= 125 amps
In right speed
What happened when the rate is just right?
The MIG welder was in decent settings; it will produce flat weld is even gaps. It will not protrude from the metal surface too much. Additionally, the beads are almost uniform in size. And off course, they penetrate the work surface well.
In high speed
In extreme speed, the beads or wire become uneven, full, and discontinue. There is a consistent difference in each bead that this welder machine creates. The main reason for this is the welding wire is coming too fast, so the heat is not applying in the same manner. The metal is not melting and feels like the wire is pushing. Also, some random sounds were started to popping from the machine. Overall, you won’t see any formed puddle on the sheet, along with no welds that were thoroughly attached to the background. This type of wildings is fragile and risky for the work.
In low speed
This time our welder speed settings were very low. From the beginning, the welder was started to sound hissing just like air liking from a cycle tube. But the exciting thing was the wire burning out before we even not touch the sheet. Anyway, when we start to weld, we could make 2/3 beads ok, but others were disappointing. The machine wire was not coming out fast as we needed. For this, you have to move the wire slowly to form the puddle well.
Welding without the aid of shielding gas
This is the common mistake done by many welders. So, we turned off the shielding gas bottle and tried to run the beads. But soon, the welder machine started to popping and hissing a lot and massive amount of sparks and slag flying from the workspace.
Usually, shielding gas cleans the puddle weld and keeps things from entering the weld, which can make it weak. So, when you weld without shielding gas, the beads become porous and blackish. So whenever you see one of these checks, the condition of gas tank first.
Using rusty wire could cause your wired popping in the metal sheet. Check the cable well, and if found any grim or rust, clear that out completely.
Check the liner
Check the lead of your welder or the liner that comes out from the welder and goes to your weld gun. Over time this one could block by dirt and grime and cause trouble. With the wire, keep the lead also clean. If still, you see weird popping, replace it, and get a new one.
So, these are the reason that could MIG welder popping while welding. Beginners need to practice more and get control over to weld perfectly every time. If still, you are facing complications, consult with an expert. Your machine properly needs a replacement or repayment. Always wear safety gear before working.