Fusion is a general welding term to describe two pieces of metal, of similar consistencies and melting points, that melt into one another to complete a weld. When you are using arc welders like MIG and TIG welders, it is important that you know how to properly control the amount and quality of fusion to achieve solid, full-penetration welds in your metal workpieces. Often times you may experience poor fusion from the following situations: low voltage, slow wire speed, dirty base metal, excessive wire stick out, and cold base metal. Below, we show you how to easily avoid these issues to achieve increased fusion.
If your welder is running on a low voltage power, just adjust your voltage output to a higher setting. If you are experiencing a slow wire speed, adjust the wire speed to a faster setting. If your base metal is dirty or contaminated, make sure you remove any and all remnants of rust, paint, oil, grease, dirt, grime, or anything else that may remain on the metal’s surface, making it unfit for a clean weld. For excessive wire stick out, move the contact tip of your welding gun closer to the surface of the workpiece, thereby shortening the excess wire. If your base metal is too cold due to the fact that it is a large piece, like a cast piece, it is best to preheat the metal with a torch so it can absorb an appropriate amount of heat prior to welding. If you adhere to these rules, you will have an optimum fusion amount when you are welding your metal pieces together.
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