Welding guides
Parts, troubleshooting, equipment, and life in the trade. Browse by topic or search below.
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Why Flap Discs Explode: RPM Ratings, Grinder Mismatch, and Storage Problems
Learn why flap discs explode, including grinder RPM mismatch, overspeed operation, humidity damage, storage mistakes, side-loading failures, and abrasive safety problems.
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Why Plasma Cutters Randomly Lose Arc: Common Causes Most Shops Miss
A plasma cutter that randomly loses arc usually points to air pressure drop, worn electrodes, nozzle damage, torch lead faults, work clamp resistance, moisture, or transfer arc problems. Use this checklist before…
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Torch Tip Popping During Cutting
Torch tip popping during cutting is commonly caused by blocked tip passages, gas pressure imbalance, overheating, loose tips, or flashback-related flow problems.
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Why Flux-Cored Wire Worm Tracks Happen (and How to Stop Them)
Flux-cored wire worm tracking creates elongated porosity tunnels and gas channels in FCAW welds. Learn the most common causes, troubleshooting steps, and what to inspect before replacing liners, tips, drive rolls, or…
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Stick Welding Undercut Troubleshooting
Stick welding undercut is commonly caused by excessive amperage, fast travel speed, incorrect rod angle, long arc length, and poor weave technique.
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Stick Welding Excessive Slag Inclusion Causes
Stick welding slag inclusion problems are commonly caused by poor slag removal, low amperage, incorrect rod angle, improper restart technique, and bad joint preparation.
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Push-Pull Gun Wire Feeding Problems
Push-pull gun wire feeding problems are commonly caused by liner drag, incorrect drive roll tension, spool drag, feeder synchronization issues, and worn contact tips.
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MIG Birdnesting Troubleshooting Guide: Causes, Fixes & Wire Feed System Compatibility
MIG wire birdnesting is one of the most common wire feed failures in both hobby and production welding environments. The problem usually appears as tangled welding wire packed behind the drive rolls…
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Plasma Cutter Air Pressure Too High Symptoms
Excessive plasma cutter air pressure can cause unstable arcs, bevel cuts, double arcing, consumable wear, torch overheating, and poor cut quality.