VR Welding Simulator

5 Common Welding Challenges and How to Overcome Them

Welding is a complex process that requires great skill. Skilled welders are very important to any organization – especially in harsh environments where safety needs to be top of mind. But skilled welders are hard to find and even more difficult to retain.

A welder with a good eye, steady hand, and knowledge of how to make proper welds is no longer enough. Welders today need to be aware of the environment in which they are working and have a strategy for overcoming a variety of challenges. Whether you are welding indoors or out, whether you are welding aluminium or titanium, there are common welding problems that arise in any environment.

By being aware of these problems, you can prevent your projects from stalling or worse yet, prevent major injuries and damage to the products that are made from defective welds.

In this article let’s go through 5 common welding challenges and how to overcome them, read on for more!

Challenge 1: Distortion

The heat of welding will cause the metal to expand, then cool and contract. When you weld on a flat surface, this can cause the metal to warp or distort because it cools unevenly. This is why welders often have to deal with distortion.

If the metal joint is deformed or warped after cooling down, this can affect the quality of the welds. The metal may crack or fail due to stress.  And even if it doesn’t fail right away, it will eventually wear out over time because of the stress on the metal joint.

Challenge 2: Cracking

Cracks can be a huge problem for welders. Cracks in welds can occur for a variety of reasons, but it is often the result of poor-quality control. This can include contamination from rust, paint, oil or dirt on the surface being welded.

Cracks also can occur when the metal expands and contracts from the heat too quickly, which is known as thermal shock.

Challenge 3: Porosity

Porosity occurs when gas gets trapped in the weld, leaving behind small holes. It can happen at any stage of the welding process and can weaken the weld strength.

 Some of the most common causes for porosity are: 

  • Inadequate shielding gas: If your shielding gas is not at adequate pressure or flow, it can form air bubbles within the weld and cause porosity. 
  • Contamination: When contaminants such as rust, paint or oil remain on the surface of the metal being welded, they can cause porosity.

Challenge 4: Spatter and Slag

One of the most frustrating issues for welders is spattering, which can cause poor bead appearance. Slag is another issue; it’s an unwanted layer of oxidized metal that forms on top of the weld bead.

Both problems create extra work for welders, who need to grind off slag before they can apply filler material. In addition, these contaminants can contaminate the weld pool, which affects its quality. They can occur due to too much current, improper voltage settings or incorrect wire feed speed.

 Challenge 5: Undercutting

When the welding process begins, the weld metal doesn’t stick to the base metal at first. It takes time for the molten metal to stick to the base metal, and this is known as starting penetration.

Undercutting happens when the molten weld pool penetrates too far into the base metal. As a result, the undercut creates a feather edge that is not well bonded to the base material. The most common cause of this defect is improper travel speed, electrode angle being too acute, and too much voltage being used.

How Can a Welding Simulator Help Overcome These Challenges?

The tricky part about welding is that it has to be done right the first time. If you don’t have the proper technique, you may end up having to cut out scrap welds, which can be frustrating and costly when you’re working on a real project. For this reason, a welding simulator can go a long way towards helping get the job done right and troubleshoot some common challenges that might occur during the welding process.

A welding simulation software allows the user to experience the welds that they are going to produce before actually performing them on a real object. It enables them to try different techniques and learn from their mistakes without risking harm to themselves or any other person.

It provides a virtual environment for skill development through practising welding techniques and improving on them. The user gets real-time feedback on how well they are performing, as well as tips on how they can improve their performance. If you want to know more about our state-of-the-art Phygital Welding Simulator, click on this link.


Leave a Comment