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CO2 welding machine fault summary

The failure of CO2 welding machine is mainly caused by the wear of the mechanical part of the equipment and improper adjustment during use. The main parts of the fault mostly occur in the connection of the wire reel, the V-shaped groove of the wire feed wheel, the pinch wheel, the wire feed nozzle, the spring hose, the contact tip, the welding gun hose, the nozzle and the ground wire.

CO2 welding machine fault summary——wire spool

The main faults of the welding wire reel are that the welding wire is easy to loosen, the wire feeding motor has overload phenomenon, the wire feeding is uneven, the arc is unstable, and the welding wire is easily stuck on the contact tip, as shown in Figure Wire spool failure. The reason for the fault that the welding wire is easy to loose is that the brake of the wire reel is too loose; the reason for the fault that the wire feeding motor is overloaded is that the brake shaft of the wire reel is too tight, so that the welding wire cannot be output normally.

Wire spool failure

CO2 welding machine fault summary——V-groove for wire feed rolls

The failure of the V-shaped groove of the wire feed wheel is mainly due to the uneven wire feeding speed and the deformation of the welding wire during transportation, and sometimes it may be difficult to feed the wire, as shown in Figure V-groove failure of wire feed roll. The reason for this failure is that the V-shaped groove of the wire feed roller has been worn or the V-shaped groove itself is too large. In addition, if the V-shaped groove is too small, the welding wire will be deformed due to extrusion or even unable to output the welding wire normally, resulting in difficulty in wire feeding. 

V-groove failure of wire feed roll

CO2 welding machine fault summary——Pinch wheel

The failure of the pinch roller is mainly manifested in the deformation of the wire feeding, the difficulty in feeding the wire, the rapid wear of the wire nozzle, and sometimes the wire feeding is uneven, as shown in Figure Pinch wheel failure. The main reason for this failure is that the pressure of the pinch wheel is too large or too small. When the pressure is too large, the output space of the welding wire becomes smaller, and the welding wire is deformed by the pressure. The deformed welding wire cannot be output normally, which leads to the accelerated wear of the welding wire nozzle; when the pressure is small, the power of the output welding wire is not enough, and the feeding time of the welding wire is fast. Slow, the wire feeding speed is uneven.

Pinch wheel failure

CO2 welding machine fault summary——wire feeder

The failure of the wire feed nozzle is mainly manifested in that the welding wire is easy to bend, the feeding of the welding wire is not smooth, the frictional resistance of the welding wire is large, and the feeding of the wire is hindered, as shown in Figure Wire feed nozzle failure. The main reason for this failure is that the hole of the wire feeder is too large, or the distance between the wire feeder and the wire feeder is too large, and the welding wire has room for movement during the conveying process. However, if the wire feeding nozzle is too small, the frictional resistance between the welding wire and the nozzle hole will increase, resulting in resistance to the feeding of the welding wire.

Wire feed nozzle failure

CO2 welding machine fault summary——spring hose

The failure of the spring hose is mainly manifested in that the welding wire is easy to bend, and the wire feeding is sometimes blocked. This is caused by the inner diameter of the hose being too large, and the swimming gap of the welding wire increases when it is too large, so the welding wire is easy to bend. Large frictional resistance and blocked wire feeding are also among the faults. The reason is that the inner diameter of the hose is too small or is blocked by dirt, which needs to be cleaned up in time. The reason for the poor wire feeding is that the hose is too short, the welding wire cannot be stretched and the running is not free; if the welding wire is too long, the frictional resistance of the welding wire will also increase, making wire feeding difficult or even blocked, as shown in Figure spring hose failure.

spring hose failure

CO2 welding machine fault summary——Contact tip

When long-term welding leads to the wear of the contact tip or the increase of its own aperture, the contact point between the welding wire and the contact tip will often change.If the aperture of the contact tip is too small, the friction between the welding wire and the hole wall will increase, so that the welding wire is not smooth during the feeding process, and in severe cases, the welding seam will be caused. A clipped copper is produced, as shown in Figure Contact tip failure. 

Contact tip failure

CO2 welding machine fault summary——Welding gun hose

If the bending radius of the welding torch hose is too small, the frictional resistance of the welding wire in the hose will increase, and the normal feeding of the welding wire will be hindered, sometimes resulting in uneven speed or the welding wire cannot be sent out at all, as shown in Figure Welding torch hose failure Show.

Welding torch hose failure

CO2 welding machine fault summary——Nozzle

If the spatter is too large during the welding process, the spatter will block the nozzle, which will cause poor gas protection effect, which will easily cause pores in the welding seam, and the arc during welding will be unstable and uneven; if the nozzle is loose, There will be air inhalation during welding, and the protective effect of the gas will also deteriorate, resulting in pores during welding, as shown in Figure Nozzle failure.

Nozzle failure

CO2 welding machine fault summary——ground connection

If the ground wire is loose during welding or there is obvious rust at the contact with the weldment, the contact resistance increases, and arc ignition cannot be performed, or the arc combustion is unstable after arc ignition, as shown in Figure Ground wire connection failure, At this time, the grounding of the welding machine (workpiece) should be sufficiently good.

Ground wire connection failure