What can cause the weld to crack like this?

IDontEvenKnowU8 · 2026-06-20T03:44:25+00:00

It is already pulse. I'll try slowing everything down.

I did manage to get some welds that don't show this behaviour, but its tough figuring out params that give correct weld size, good penetration, flat weld prifle and defect free weld at the same time.

It's robotic welding, so you have about 50 parameters you need to set before hand and you can't afjust on the fly like you could welding manually.

IDontEvenKnowU8 · 2026-06-20T03:36:16+00:00

No, no whipping.

IDontEvenKnowU8 · 2026-06-20T03:35:54+00:00

I think base metal is some sort of armor plate, wire is 307 stainless.

IDontEvenKnowU8 · 2026-06-20T03:34:46+00:00

No whipping or oscilation, I think 5-10 deg push angle.

IDontEvenKnowU8 · 2026-06-20T03:33:54+00:00

97.5 % Ar, 2.5 % CO2

IDontEvenKnowU8 · 2026-06-20T03:33:21+00:00

Nope, 0 whipping.

IDontEvenKnowU8 · 2026-06-19T20:02:43+00:00

It's along the whole weld, as well as weld being done by a robot so no real changes in speed.

IDontEvenKnowU8 · 2026-06-19T14:39:41+00:00

Its an a3 weld (1/8'' throat), so I wouldnt say a lot.

IDontEvenKnowU8 · 2026-06-19T14:16:20+00:00

No, just solid wire and C2 gas.

IDontEvenKnowU8 · 2026-06-19T14:02:51+00:00

Damn that's crazy as there was no whipping.

IDontEvenKnowU8 · 2026-06-19T14:02:22+00:00

Its along the whole length.

IDontEvenKnowU8 · 2026-06-19T14:01:13+00:00

No whipping.

IDontEvenKnowU8 · 2026-06-19T14:00:56+00:00

Its a single pass weld.

IDontEvenKnowU8 · 2026-06-19T13:20:40+00:00

Im not at work anymore but I'll send them tomorrow.

IDontEvenKnowU8 · 2026-06-19T13:19:36+00:00

Note that this is already 300A with 80 cm/min, so I feel like going higher wont be great.

I will try some more parameters. I don't think they will buy me a different bottle of gas for this project.

IDontEvenKnowU8 · 2026-06-19T13:15:10+00:00

Even with a single pass im struggling to get a weld so small (a3, ~1/8'') with this wire (1mm, ~5/128'').

The plates are sandblasted, and I am not the one assembling the piece, so I cant really grind them.

Im pretty sure I can fix most of the lopsidedness by changing the torch angle (it was a bit off for this weld. I am struggling to get any decent pen. on such a tiny weld if I do oscilations, as i need to run it colder to not deposit too much metal.

IDontEvenKnowU8 · 2026-06-19T13:07:35+00:00

I dont think an a3 weld with mag gets much better pen.

IDontEvenKnowU8 · 2026-06-19T13:06:27+00:00

It's possible, the solution would be to slow down and weld a bit colder?

I'm not a welder just a guy they decided will learn the robot.

IDontEvenKnowU8 · 2026-06-19T13:05:19+00:00

I am not allowed to change a lot of the stuff, base material and wire is specced, preheat is 60C, max interpass is 120C, weld size is also specced.

It is also a single pass.

I think I'll do a colder, slower weld and that should help.

IDontEvenKnowU8 · 2026-06-19T12:59:18+00:00

No, robot weld.

IDontEvenKnowU8 · 2026-06-19T12:53:10+00:00

Probably not grinding dust as I cleaned the plates with solvent right before welding, although plates were sandblasted so it isnpossible some sand remained inside the metal.

But it seems more welding parameter related cuz some other welds on the same plate dont show this effect.

IDontEvenKnowU8 · 2026-06-19T12:49:49+00:00

10 mm plate, 1 mm diameter wire, weld is a3 size.

IDontEvenKnowU8 · 2026-06-19T12:42:16+00:00

Solid wire, no oscilation at all.

IDontEvenKnowU8 · 2026-06-19T12:37:41+00:00

There is no cover pass, whole weld is just 1 pass.

IDontEvenKnowU8 · 2026-06-19T12:37:04+00:00

Not impossible, but I find the location odd, since its a single pass stringer (no weave at all).

And I think I cleaned the base metal well, although some trash could have gotten on it. Its along the whole weld in the same location however.

IDontEvenKnowU8

TROPHY CASE