Welding defects in submerged arc welding can be costly to fix and are far more common than many realize. A US manufacturer of heavy equipment was experiencing burn-backs, inconsistent voltage/amperage causing burn throughs and tractor stoppages mid-weld. With each weld defect, the weldment had to be transported to be ground down and rewelded to meet quality standards.

This graph, generated by Wizard View® optimization software, shows inconsistent amperage caused by poor wire delivery, which resulted in an inconsistent bead profile width.

Consistent Wire Delivery =
Consistent Welds
Wire Wizard field engineers installed the Weld Central® Optimization System to monitor welding performance at the facility. After recording some baseline data, the system detected inconsistent feeding within the wire delivery system causing a variation in parameters, resulting in burn throughs and burn-backs in the contact tip. The Wire Wizard team then optimized the wire delivery system, utilizing the Wire Pilot® Feed Assist, Wire Guide Modules and low friction conduit.

The result was consistent wire delivery that improved the consistency of the welding parameters on each full length weld, eliminating major defects causing excessive repair time. The manufacturer continues to utilize the Weld Central® System to detect any welding parameter inconsistencies in order to resolve them before they get out of control.

Need a Wizard?
Did you know Wire Wizard has a dedicated team of welding engineers available to help solve complex welding challenges? If you need a Wizard to solve your welding troubles, email the details to our field engineers at ineedawizard@wire-wizard.com.