10 Most Common Welding Mistakes

Welding is fantastic, but it can be challenging if you are just starting out. Many things can go wrong and cause you a headache, but that's the part of mastering any skill, including welding.

Welding mistakes are not uncommon, especially for new welders and beginners. However, even the most experienced welders occasionally make mistakes.

That's why we compiled a list of the 10 most common welding mistakes, with detailed explanations and solutions. So, don't lose your hope. Read the article to understand what went wrong and what you can do to produce sound and successful welds every time.

MIG Welding to Repair Welding Table
Source: https://www.youtube.com/watch?v=LITz7kLo-a4&t=1457s

Is Welding Hard to Learn?

Welding is one of the trades that transformed from a highly professional, industrial occupation into something you can do at home, for your DIY projects or general metal fabrication. Methods such as MIG welding highlighted the ease of use for ordinary users, making welding much more beginner-friendly.

However, there are numerous factors to keep track of, including welding equipment, parameters, filler materials, metal preparation, and technique, to name a few. Failing at one of these steps during welding can lead to mistakes that cause welding defects.

Source: https://weldingofwelders.com/welding-defects-and-their-types/

That's why many consider welding to be a highly challenging occupation, but it doesn't have to be that way. As long as you understand the fundamentals and why things go wrong, welding can be a breeze.

So, let's explore the mistakes and what you can do to avoid them.

TIG Welding Tubing
Photo by @sakramencki.blysk (TikTok)

10 Most Common Welding Mistakes and How to Avoid Them

Welding mistakes happen, even to the most experienced welders. There are just a lot of things to consider before striking an arc, but once you get the hang of it, you are set for success.

The most common welding mistakes many make are:

• Using old or faulty welding equipment

• Using the wrong filler (electrode) for the job

• Buying equipment based on the price

• Skipping welding preparation

• Failing to control the heat

• Overlooking welding safety

• Using the wrong welding technique

• Using the wrong shielding gas for the job or providing poor coverage

• Disregarding consumables and their state

• Overlooking and ignoring maintenance

Let's further explain all.

1. Using old or faulty welding equipment

This is a mistake many older or more experienced welders tend to make. Instead of following the new trends and technological advancements in the world of welding, some welders stick to their old reliables.

The truth is, older transformer welders are real workhorses, and it's not uncommon to see some of the old Lincoln welders still in operation. However, innovation has brought us new technology that is much more energy-efficient and offers various features and modes, making everyday welding much easier.

A multiprocess welder makes everyday welding easier and more versatile.

For example, new inverter welders are much lighter and more efficient. They have much lower energy consumption while providing QoL features that make welding easier. These machines introduced features such as pulsed welding for improved heat control, smart MIG for more effortless operation and training, as well as higher speed, lower primary amperage draw, and reduced preparation time.

Therefore, don't be afraid to invest in new technology, especially if you are running old, faulty machines. Faulty equipment, such as welders, wire feeders, or generators, can yield inconsistent results and unstable arcs, leading to various defects.

DualPulse MIG Welding with YesWelder DP200
Source: https://www.youtube.com/watch?v=bkcNM-Z9xsc&t=17s

2. Using the wrong filler for the job

Depending on the welding process being used, the filler metal or electrode must be compatible with the base metal. Using the wrong electrode is one of the most common mistakes many beginners make, and it will significantly affect the structural integrity and properties of the welds.

Filler metal, among others, differs in composition, size (diameter), and coating. So, if you are welding mild steel, you'll need a wire or rod specifically designed for mild steel (ER70S-6 ); if you are welding aluminum, you'll need an aluminum wire or rod (ER4043 ); and if you are welding stainless steel, you'll need a stainless steel wire (E308L ). Matching the composition is crucial to ensuring solid results.

ER308L 2LB Spool Stainless Steel Solid MIG Welding Wire

The size of the electrode or wire also matters. The thicker the wire is, the more heat it needs to melt, and it provides more filler metal. So, using a thick electrode for thin metals with small joints can cause overheating and overwelding. Meanwhile, using a thin wire for thick metals and wide gaps can be time-consuming or result in inadequate penetration.

Electrode coating can also affect welding. For instance, E6010 is known for its penetration, E6013 is popular for its forgiving arc for beginners, while E7018 works great for heavy equipment repairs.

Using the correct filler or electrode for the given metal or application is crucial for producing sound welds.

Beginner-Friendly E6013 Stick Welding
Photo by @country19424 (TikTok)

3. Buying equipment based on its price

When purchasing welding equipment, whether it is wire, accessories, or a welder, basing your decision solely on price is the wrong approach. The cheapest options on the market are often flawed, especially when it comes to consumables, while pricier equipment may be cost-ineffective for you.

For instance, cheap wires often have inconsistent diameters along their length or are poorly spooled. While AWS standards state the composition, the quality will vary depending on the manufacturer. Therefore, inexpensive wires and equipment can often have issues with feedability and performance due to poor quality control.

Meanwhile, industry-grade, expensive equipment is not always a cost-effective solution. Unless you plan to recoup the investment through your work, buying expensive equipment for occasional or hobby use is not worthwhile.

As a solution, we recommend browsing the YesWelder website. Our machines, such as the YesWelder DP200 MIG Welder , offer convenient features for both beginners learning to weld and professionals seeking advanced capabilities, including dual pulse MIG. All that at a reasonable price, so you get the best value for it. The same applies to all equipment we offer.

Firstess DP200 Multi-Process DualPulse™ MIG Welder

4. Skipping weld preparation

Weld preparation is half the work. The more time you spend preparing, the less time you'll spend cleaning up the mess or reworking. Therefore, before lighting the arc, you should:

• Thoroughly clean the surfaces: Remove all dirt, rust, moisture, oil, or other contaminants that may affect the quality of the weld.

Thoroughly Clean the Metal Surfaces before Welding
Source: https://www.youtube.com/shorts/N-_WtwlE0Xs

• Check the ground and connections: Poor ground, cables, or connections can create an unstable arc with spatter and inconsistent results.

• Ensure proper part fit-up: An even gap across the joint will yield a uniform weld.

• Tack the pieces if necessary: Tacking the pieces will keep them in place, ensuring spatter-free, high-quality welds.

• Follow the WPS: If specified, always adhere to the weld procedure specifications to ensure the highest quality of the welds.

Using the proper weld preparation will significantly improve your final results.

Welding Results over Dirty vs. Clean Material
Source: https://www.youtube.com/watch?v=CLh6kPC_RoI

5. Failing to control the heat

Trying to weld heat-sensitive metals such as aluminum, stainless steel, or high-carbon steel, without controlling the heat, can be challenging. Stainless steel tends to warp, distort, or lose its corrosion resistance if overheated. Aluminum requires the right amount of heat to avoid burn-through or lack of fusion, while high-carbon steels can crack if heated and then cooled too rapidly.

Burn-Through Caused by Excessive Heat When MIG Welding
Source: https://www.youtube.com/watch?v=_lB4h8qgoqY&t=30s

One way to control heat is to use pulsed welding. Pulsing delivers short bursts of energy rather than continuous heat, which can help prevent overheating.

Also, be sure to use the correct parameters, such as amperage (wire feed speed) and voltage, for the given material type and thickness. If you're unsure what the right amount of heat is, you can always practice on the scrap metal. If you are new to welding and don't know where to start, use a welder with smart MIG, or synergic MIG, which automatically adjusts voltage and WFS. We recommend checking out the YesWelder MIG205DS , which includes these features for easy adjustment.

MIG-205DS-Pro Multi-Process MIG Aluminum Welder

Heat treatment is mandatory with high-carbon steels. Preheating the pieces reduces the thermal stress associated with rapid heating, while post-weld heat treatment (PWHT) promotes slow cooling and helps relieve residual stress. Heat treatment and low-hydrogen fillers will minimize the risk of cracks. However, high-carbon steels can sometimes crack even when you do everything right.

Heat Treating High Carbon Steel
Source: https://hackoutdoors.com/heat-treating-high-carbon-steel

6. Overlooking welding safety

Welding is a hazardous profession that carries significant risks. An arc produces extreme heat and UV/IR radiation, while burning metals create fumes and sparks. One of the biggest mistakes any welder can make is overlooking welding safety.

Finishing a few quick repairs without a long-sleeved jacket or a proper welding helmet can cost you severe burns or arc eye. Therefore, even if you are working on a few small and quick projects, always wear the appropriate PPE.

A welding helmet, such as YesWelder M800HP , will keep your eyes and face safe, while the jacket and gloves protect your skin from burns. These are a must-have for any welder.

LYG-M800HP True Color View Auto-Darkening Welding Helmet

For extra safety, consider using a welding respirator when working in confined spaces, headphones to protect your ears from noise, and safety glasses. While not always mandatory, these can provide long-term protection.

Use a Respirator When MIG Welding in Confined Spaces
Source: https://www.youtube.com/watch?v=ba5YcLAPTqw

7. Using the wrong technique

Every welder has a preferred style and technique when moving the torch, but some ground rules differentiate good welds from poor ones. New welders tend to wobble the torch, change speed, or angle during the pass, and each of these actions can affect the quality of the weld.

Like any skill, welding requires practice. Although it can take years until you perfect your welding, doing the right things can help you advance. The final goal is to achieve consistent welding speed and travel angle.

Keeping a steady hand and smooth travel speed during welding.
Source: https://www.youtube.com/watch?v=gc9fBVq9NlE&t=589s

While pushing or pulling will depend on the welding method and application, maintaining a steady hand and consistent speed across the joint will ensure the best results.

Visual inspection can easily tell you there is something wrong with your technique. If you see uneven, curved, or ropey welds, you are probably doing something wrong, likely due to a technique issue.

More experienced welders often overlook the value of training or retraining. Technology is constantly evolving, and learning new skills or mastering the ones you possess can give you a competitive edge over other welders and employees.

Learning the new welding skills.
Photo by @that40yearoldcarguy (TikTok)

8. Wrong shielding gas or poor coverage

Welding methods such as MIG or TIG welding require external shielding gas protection. Shielding gases, such as argon, helium, or CO2, protect the weld puddle from atmospheric contamination, keeping your welds clean and porosity-free.

Types of Welding Gases
Source: https://www.mechdaily.com/welding-gases/

Keep in mind that different gases and mixtures produce different welding results. Using a one-size-fits-all approach is a mistake many welders make when selecting shielding gas. So, here are some general solutions:

• Pure CO2: 100% carbon dioxide works well with MIG welding on thick mild steel. It produces good penetration, but it also causes excessive spatter. Use it as an affordable option for MIG welding and mild steel.

• Argon/CO2: 75% Argon and 25% CO2 is one of the most commonly used shielding gas mixtures in MIG welding. It combines the cleanliness and protection of inert argon gas with the penetration and arc stability of CO2. Use it to MIG weld mild steel.

• Pure argon: 100% argon is a must-have when TIG welding or MIG welding aluminum or other non-ferrous metals. TIG welding requires inert gases to protect the heated tungsten electrode from contamination. On aluminum, argon doesn't react with the surface to create a protective oxide layer.

TIG Welding Aluminum with Pure Argon
Photo by @dan_thecreator_ (TikTok)

• Argon/helium: Adding helium improves arc stability and penetration of argon. Helium is another non-reactive gas, making this valuable mixture for TIG welding thicker pieces that require better penetration. Helium shows similar performance to CO2, but it is much pricier, so it is not commonly used in MIG welding.

• Tri-gas mixtures: Stainless steel welding works great with a tri-gas mix of argon, helium, and CO2. Alternatively, you can use an argon-rich two-gas mixture with 2-3% CO2.

Also, pay attention to coverage. Using too high a gas flow creates turbulence that sucks in the contamination. When cleanliness is crucial, use a gas lens kit and employ back purging.

TIG Pipe Welding with Gas Lens and Back Purging
Source: https://www.youtube.com/watch?v=mQUGwS0EuIk&t=2s

9. Disregarding consumables

As the name suggests, consumables are the parts that are used up during welding. For instance, that's your nozzle, contact tip, collet body, and electrodes, wires, or TIG rods. Heat damages these parts over time, and many welders use them excessively, which is a common mistake.

As nozzles wear out, they can affect the wire feed or cause the wire to fuse to the opening. Worn contact tips cause keyholing, leading to irregularities in the arc from poor electrical pickup. Meanwhile, worn or damaged liners can cause wire clogs or kinking during their path. The damaged collet body provides poor shielding gas coverage.

Nozzle and Contact Tip Clogging
Source: https://www.youtube.com/watch?v=iWieTM0PKqI

Therefore, before welding, check your consumables. Replace them whenever you notice signs of damage to avoid unscheduled downtime, unexpected weld defects, poor arc performance, or improper shielding gas coverage.

Regarding wires and electrodes as part of consumables, pay attention to storing and handling. Keep your electrodes away from dirt and moisture, as they can rust or pick up contamination. Store filler metals in a dry, clean area with a relatively constant temperature.

Always store filler metals in a dry, clean area.
Source: https://www.youtube.com/watch?v=bW-5YFV4sK4

10. Overlooking the maintenance

Spotting a worn-out part will help you schedule the maintenance and avoid unnecessary downtime. Also, it will minimize the risk of unwanted defects and further damage to your machine.

Many occasional or DIY welders tend to overlook the maintenance. Instead of just firing up the machine and using it, take some time to check the essential parts, like the MIG gun, TIG torch, wire feeder, cables, and connections.

Worn parts, cables, and connections can yield unstable and unpredictable results. Nonetheless, they also pose a safety risk and can cause total failure if you fail to notice them early.

You don't have to be an expert to inspect your equipment and figure out that it is time to replace some things. It doesn't take much to inspect the gun, its consumables, cables, connections, gas regulator, and hoses.

Inspect the gun, cables, and gas system before welding.

Tips To Avoid the Most Common Welding Mistakes

Final Thoughts

Mistakes are a part of life, and they can happen to anyone, even the most experienced workers. That's also the case with welding, as there are small things that can ruin your project.

The key to avoiding the most common welding mistakes is understanding why they happen. Our goals were to explain exactly why things occur and what you can do to prevent them.

By following the proper practices and employing safety, you can produce sound, everlasting welds. All it takes is knowledge, some time, and patience, and you are set for success.

🧐10 Most Common Welding Mistakes FAQ

1. How to prepare for welding?

Proper weld preparation is essential for clean, strong, and consistent welds. Always clean the surfaces, check grounds and connections, ensure correct part fit-up, tack pieces if needed, and follow the weld procedure specification (WPS). These steps reduce spatter, prevent rework, and improve overall welding quality.

2. What is the best way to weld heat-sensitive metals?

Welding heat-sensitive metals like aluminum, stainless steel, and high-carbon steel requires careful heat control to prevent warping, burn-through, or cracking. Use pulsed welding to deliver short bursts of energy and set the correct amperage, wire feed speed, and voltage for the material and thickness. Beginners can practice on scrap metal to gain experience.

👏 You may be interested in the following:

• Tips For Vertical Welding
• How To Choose The Right Welding Types
• What Makes a Welder Truly User-friendly?