Welding defects are something that manufacturers want to avoid at all costs. Here we go through some step by step procedures to help you figure out what is going wrong or to prevent a welding defect from happening in the future. If you see welding defects, it is important to understand what is going on with your robotic welding system. Here are a few steps you can take. First, check for shielding gas leaks and flow. Make sure the shielding gas hose is intact and all of the fittings are tight. Use a soap bubble test to ensure there are no leaks. Check for welding spatter. Welding nozzles can get bogged down over time, so remove and clean the nozzle often. This is commonly completed by using an automatic torch cleaning station. Replace welding tips and liners regularly. Welding contact tips should be replaced daily to ensure the wire feed is smooth and consistent. Replace welding wires as needed, typically every few weeks. Check the welding wire. Welding wire should feel strong as it exits the welding gun, you should not be able to stop the wire by hand. Be sure to change or flip drive rolls occasionally. Lastly, check stick out height and push-pull angles. Typical stick out height is 5/8 inch to 3/4 inch. Trim the wire to the proper length for optimal welds. Adjust the push or pull angle to the appropriate angle based on your application. This is usually around 15 degrees. After completing these steps, you should be able to return to creating strong and consistent welds. If you are interested in a welding robot? Please visit us at https://www.robots.com/applications/w... for more information, contact representatives at RobotWorx at 740-251-4312.