Most common errors in the use of welding burners

What problems can occur during welding?

Wire jamming in the torch

Symptoms: intermittent arc, irregular wire feed, jerking torch in the welder’s hand.

Most common causes:

1. Clogged or damaged liner – metal shavings, rust, or deformations increase friction.
2. Worn contact tip – an oval hole slows down the wire.
3. Incorrect drive roll tension – wire deforms into a “bird's nest”.
4. Poor-quality or rusty wire – surface dust clogs the liner.

Prevention and solution:

• Blow out the liner with compressed air once per shift, or replace it after 150 kg of wire.
• Always use a Teflon liner for aluminum and stainless steel; for steel, a quality steel spiral is sufficient.
• Set the drive roll pressure so the wire is not flattened – a simple test: you should be able to stop the wire with your fingers without deforming it.
• Store spools in a dry place; discard any rusty wire.

Reduced weld quality due to poor torch

Symptoms: pores, cracks, unattractive surface, excessive metal spatter.

Most common causes:

1. Underdimensioned torch – a hobby torch used at industrial current overheats, warps the neck geometry and loses shielding.
2. Gas leaks – damaged O-rings, cracked hose or loose threads.
3. Cheap or non-original consumables – poor quality brass alloys conduct current and heat less effectively.

Prevention and solution:

• Choose a torch at least 20% more powerful than your usual working current.
• Check the gas connections for leaks weekly using soapy water.
• Invest in original CuCrZr tips and nozzles – they last longer and keep the arc stable.

Incorrect current and gas settings

Symptoms: lack of penetration, burnt edges, porosity, excessive spatter.

Typical mistakes:

1. Too low current – the weld sits “on top”, weak bonding.
2. Too high current – material burns through, edges deform.
3. Insufficient gas flow – oxygen enters the weld pool.
4. Too high gas flow – turbulence drags atmosphere into the arc.

Prevention and solutions:

• Follow recommended values: for example, for steel wire Ø 1 mm, 90–120 A and 8–12 l/min argon/CO₂ is standard.
• For thin sheets, use the "synergies" or pulse function to optimize current and voltage.
• For aluminum, increase gas flow by 10–15% and use a shorter nozzle to protect the weld pool better.

Nozzle damage and its effects on welding

Symptoms: uneven shielding, spatter cone on the nozzle, sparking when the nozzle touches the material.

Most common causes:

1. Weld spatter stuck on the nozzle – disrupts gas flow and narrows the opening.
2. Overheating – nozzle warps or cracks.
3. Physical impacts – bent nozzle misaligns gas flow with the wire.

Prevention and solutions:

• After each shift, clean with a brass brush and apply anti-spatter spray.
• Use water-cooled nozzles with thicker walls for currents above 250 A.
• Store torches in an upright position to avoid nozzle deformation.

Key Recommendations in Conclusion

1. Follow a maintenance schedule – regular cleaning and replacement of consumables cost less than repairing the entire torch assembly.
2. Train the operators – most errors arise from incorrect settings of current, gas flow, and roller pressure.
3. Watch visual and acoustic signals – changes in arc sound, gas leaks, or wire jerking are early warnings you shouldn’t ignore.

A properly set, maintained, and adequately rated torch will reward you with clean, defect-free welds, higher productivity, and lower operating costs.