Rachel Fewings Shares How to Troubleshoot Common Issues in Welding Projects 
                     Welder
RACHEL FEWINGS 
SHARES HOW TO 
TROUBLESHOOT 
COMMON ISSUES IN 
WELDING PROJECTS 
www.rachelfewings.com
Introduction
Welding is a precise craft, but even the 
most skilled welders encounter issues that 
can affect the quality of their work. 
Whether you're a beginner or a seasoned 
professional, understanding how to 
troubleshoot common welding problems is 
crucial to achieving flawless results. In 
this ppt, Rachel Fewings explores some of 
the most frequent issues welders face and 
provides practical solutions to overcome 
them.
Identifying and 
Resolving Porosity in 
Welds Porosity, the presence of tiny gas pockets in 
a weld, is a common issue that weakens the 
integrity of the weld. This section will 
discuss the causes of porosity, such as 
contaminated materials or improper 
shielding gas, and provide steps to eliminate 
it. Rachel Fewings emphasizes the 
importance of maintaining clean surfaces 
and ensuring proper gas coverage to prevent 
this issue.
Preventing 
and 
Correcting 
Weld Cracks
Weld cracks can compromise the strength 
and durability of a project. We'll delve into 
the different types of cracks, including hot 
cracks and cold cracks, and explore their 
causes. Solutions like adjusting cooling 
rates, preheating materials, and using the 
correct filler material will be discussed. 
She highlights the significance of proper 
preparation and technique to minimize the 
risk of cracking.
Addressing 
Undercut Problems
An undercut occurs when the base material is eroded, creating a 
groove along the edge of the weld. This flaw can weaken the joint 
and lead to failure under stress. In this section, we'll explore the 
common causes of undercutting, such as excessive heat or 
improper welding angle, and how to adjust your technique to avoid 
it. Rachel Fewings suggests practical tips for maintaining the right 
balance of heat and speed to produce a smooth, strong weld.
Managing 
Incomplete Fusion 
and Penetration
Incomplete fusion and penetration are serious 
issues that can result in weak welds that may 
fail under load. We'll examine the reasons 
behind these problems, such as incorrect 
electrode angle or inadequate heat input, and 
provide troubleshooting strategies to ensure 
full penetration and fusion. She shares her 
expertise in adjusting welding parameters to 
achieve solid, reliable joints.
Dealing with 
Welding 
Distortion
Welding distortion, caused by the 
uneven heating and cooling of 
materials, can warp and misalign your 
workpiece. This section will cover 
techniques to control and minimize 
distortion, such as using clamps, 
employing a backstep welding 
technique, and managing heat input. 
Rachel Fewings emphasizes the 
importance of careful planning and 
technique to keep your project in shape.
THANK 
YOU
www.rachelfewings.com