MIG Welding Troubleshooting – Causes and Quick Fixes

MIG Welding Troubleshooting

A weak Mig welding machine can be caused by an unstable power supply or a damaged welding machine. So what is the main cause of the MIG welding troubleshooting? Refer to how to fix a weak Mig welder so that the welding machine works well for beautiful, durable welds right below.

Cause of Weak MIG Welding Machine

When finding out the cause of the weak MIG welding machine, you will see that the main causes are related to the power source. At the same time, the cause of choosing the wrong type of welding rod can also cause the electronic welding machine to be weak.

Here are some reasons for weak welding machine walls:

  • Using an unstable or flickering power source causes the welding machine to not generate electricity and operate intermittently.
  • When choosing a welding rod with a larger diameter of the welding rod than the welding machine, the machine quickly heats up and automatically disconnects the electrical circuit.
  • The wrong choice of welding compared to the type of welding machine in use, for example, the diameter of the welding rod is large compared to the capacity of the welding machine.
    The welding machine is weak due to various reasons, the welding rod is stuck.
For example, industrial welding machines with a capacity of 5.4KVA – 6.5KVA are usually suitable for welding rods with a diameter of 1.5mm – 3.2mm. When choosing a rod with a diameter larger than 3.2mm, the electronic welding machine will be weak.
Cause of Weak MIG Welding Machine

How to Fix a Weak MIG Welder – Troubleshooting Common MIG Weld Defects

When the Mig welding machine does not power on, does not output power or has weak welding, you need to fix it as soon as possible. This will help restore the machine to stable operation for continuous welding work in no time.

1 – Increase Welding Current Level

In case the welding current is weak, welding cannot be performed. You can adjust the welding current level to a higher level to increase the welding current.

Most welding machines today have a knob to adjust the welding current. Therefore, you only need to rotate the knob clockwise to increase the welding current. After that, you check to see if the welding machine is still weak.

2 – Check the Diode of the Welder

In the case of diodes being disabled, the MIG welder will be weak. You can use a multimeter to check whether the diodes are alive or dead. If the diodes are alive then the multimeter will have the same voltage level.

Conversely, if the diode is dead, no voltage will be displayed on the meter. In this case, you should replace a new diode to ensure that the welder works with a normal voltage current.

3 – Repair the Power cord of the Welding Machine

If you use a large power source of 10A or more, but the power lead of the welding machine is too small, making the wire unable to bear the load, causing the electronic welding machine to not enter the electricity or the voltage is weak.

At that time, you should replace the power lead to ensure that the cross-section is suitable for the amperage as well as the voltage used. This is also one of the ways to fix weak electronic welding machines to fix and ensure stable operation of the welding machine.

4 – Low Power input to the Welding Machine

In the case of low power input to the welding machine (about 20%), the electronic welding machine will be weak. You can then rotate the knob to increase the welding current curve. 

However, in the case that if the power is increased to the machine, the machine still cannot operate.

At that time, you can choose to buy a new welding machine that works when the power is low. On the market today, there are many types of electronic welding machines to meet the requirements of use.

In addition to the instructions on how to fix a weak Mig welder, you can also replace a new welder with lines from electronic rod welding machines, Mig welders or Tig welding machines.

In particular, current high-end electronic welding machines are capable of stable operation even when the current is weak.

Troubleshoot MIG Welding Problems

ProblemFixing Tips
Irregular Wire FeedCheck wire feed tension; ensure proper threading; check for wire kinks or bends
Burn-BackAdjust voltage or wire feed speed; shorten stick-out; keep nozzle distance; check contact tip
PorosityCheck gas flow rate; ensure clean nozzle and surface
Excessive SpatterReduce wire feed speed or increase voltage; use anti-spatter spray or nozzle


How to fix MIG welding troubleshooting? MIG welding can be a great way to join metal pieces together, but it can also be susceptible to problems. By being aware of the most common problems and troubleshooting techniques, you can minimize the chances of having a bad weld.

Always remember to use the proper safety equipment and to follow the manufacturer’s instructions when using MIG welding equipment.


How do I stop my MIG welder from splattering?

To reduce MIG welding spatter, your wire must be fed continuously at the proper tension, with no snagging or other restrictions. A smooth, consistent wire feed speed must be provided to achieve a clean weld. The shielding gas must flow freely at the right rate.

What causes MIG welding to sputter?

As soon as the power source detects the reduced current at the arc, it sends a surge of voltage to overcome the restricted current flow. Due to this increased voltage, poor and inconsistent weld quality is caused by popping and sputtering.

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