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Welding Burnback – Common Causes & How to Fix

Date: 01-08-2024
MIG Welding

Welding Burnback – Common Causes & How to Fix - Alphaweld

A crucial component of a successful weld is the MIG gun's wire feed. Maintaining a steady wire feed ensures consistently good welds. But what happens when the MIG wire burns back to the tip, causing burnback and abruptly stopping your work?

What is Welding Burnback?

Burnback during welding occurs when the MIG wire burns back to the tip, often due to the wire arcing at the contact tip and welding itself inside the tip. This issue is unique to MIG welding because it involves continuous wire feed through a small contact tip hole. 

Five Common Causes of Burnback and Recommended Solutions

Here are five common causes of contact tip burnback and how to address them:

Wire-Feed Speed

Setting the correct wire-feed speed is essential for a smooth weld. A feed that's too slow is one of the most common causes of burnback. If the arc melts the wire faster than it feeds out of the gun, the wire will travel back into the contact tip. Double-check your machine’s settings and increase the wire feed speed if necessary.

Erratic Wire Feeding

Erratic wire feeding can stem from several issues. The wire might have carved a groove in the tip or even welded to the tip itself. Incorrect tensioning of the filler wire can also cause this problem. Too much tension can make the wire struggle to feed and become stuck. Check your machine's parameters, remove the nozzle, and inspect the contact tip. Also, examine the liner for buildup, ensure its well-trimmed, and correctly sized.

Improper Tip Stick-Out/ Recess

The length of the tip relative to the nozzle is crucial. A tip that's too long or too short can cause problems. As a general rule, the higher the current, the more the tip should be recessed. Using a longer wire stick-out helps keep the tip away from the arc's heat. 

Improper Electrode Stick-Out

Ensure the distance between your torch and the metal is appropriate. Maintain a distance of at least a half-inch from the surface. Crowding your work is a common cause of contact tip burnback and is easy to correct.

Faulty Ground

An imperfect ground can cause burnback. If your clamps lose contact even briefly, you’ll lose voltage, but the wire will continue feeding. Always attach your grounding clamps to your workpiece instead of the table.

Get the Right Gear at Alphaweld

Operational issues can cause burnback, but using the right equipment significantly lowers the chances. High-quality, durable contact tips can help reduce burnback and decrease downtime.

At Alphaweld, we are committed to delivering high-quality MIG guns and consumables with welders' needs in mind.

Call us on (08) 9456 8000 or send us an online enquiry if you need expert guidance on the best gear to tackle any welding burnback issue you may be experiencing.