The Secrets to Better-Looking, Stronger Welds

Most farmers can lay welds that are functional, if not “beautiful.” Here are seven tips to improve both the quality and appearance of welds:

1. The flux on the exterior of welding electrodes absorbs moisture from the air. Even if the flux doesn’t look swollen or flaky, it can have enough moisture to corrupt welds. Degraded flux causes sputtering arcs or bubbly welds. Many farm supply stores sell round, plastic tubes with threaded, O-ring-sealed plastic caps that protect welding rods from atmospheric moisture.
   

   

   (Dan Anderson)

2. Spools of welding wire inside MIG welders are somewhat susceptible to corrosion due to humidity, especially if not used frequently or if stored in buildings susceptible to condensation on chilly mornings. Dirty welding wire feeds erratically and makes it difficult to maintain a steady arc. Welding supply stores sell felt “wipers” that clip over the welding wire just ahead of the welder’s wire-feed assembly to remove minor corrosion.
3. Always lay out the cable between a MIG welder and the welding site with as few curves or loops as possible. If the arc of a MIG welder starts stuttering, or the wire feeds from the nozzle erratically, make sure the wire-feed cable doesn’t have a tight loop that restricts wire movement.
   

   

   (Dan Anderson)

4. MIG welding requires unpainted, uncorroded, clean metal surfaces and works best if the ground clamp grips bare metal within 6' of the welding point. Difficulty initiating an arc, or a weak arc while welding, is symptomatic of a poor ground when MIG welding.
5. Control of the pool of molten metal at the arc is critical whether arc or MIG welding. For that reason, professional welders get up close and personal to their work, often positioning their welding mask only a 1' or 2' from the arc. It is human nature to keep the intense, superheated arc at arm’s length, but welds improve if the welder can see clearly what they’re doing.
   

   

   (Darrell Smith)

6. Welders who wear glasses, especially with bifocal or trifocal lenses, often have trouble seeing the pool while welding. Welding supply stores sell magnifying lenses for welding helmets that can improve vision while welding. Some bifocal or trifocal wearers get better welds by removing their glasses before welding and holding their face closer to the weld to gain clearer vision.
7. Welding gloves not only protect hands from sparks and sunburn, but they also allow a welder to steady a welding rod or MIG nozzle with their free hand. One-handing a MIG nozzle or welding electrode creates unsteady arcs and erratic welds.