Common Welding Mistakes to Avoid

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Common Welding Mistakes to Avoid

A common operation involved in steel and steel services is welding, and at Wasatch Steel, we’re here to keep you well-stocked and safe during this process. We have a wide selection of products and safety equipment for each of the major forms of welding, plus the expertise to assist you with any special needs.

What are some of the most common mistakes we see made during the welding process? Here are a few, plus how to stay away from them.


Too often, the metal itself isn’t properly prepared before the welding begins. This includes areas like grinding or removing paint, rust, dirt and other surface contaminants. It could also involve grinding out cracks, sometimes even beyond what can be seen by the naked eye.

Failing to properly clean a metal to be welded will leave you with a contaminated and possibly weakened weld. Over time, material will continue cracking even after the weld is made if cracks aren’t ground out.

Thick Materials

Material over a quarter of an inch in thickness should usually take multiple welding passes. Trying to do it all in one pass by cranking the current and moving slowly over the piece may appear to work, but it will usually result in the filler metal not properly bonding to the base metal.

Worn Out Metal

There are some cases where metal is so weak that welding isn’t going to solve the problem anyway. If a piece is broken more than once or in the same area, this metal likely needs to be reinforced before welding can take place.

Electrode and Wires

The right electrodes and wire are vital no matter which welding process is being used. Certain stick electrodes are used for different applications, and the results will suffer if you use the wrong ones. Our technicians can help with this. It’s also important to take proper care of electrodes and wires, including storing them in sealed containers to keep moisture out.


Areas like push versus pull, the gun and electrode angle, the travel speed and the arc length can all cause problems in certain situations. If you’re unsure of a technique, be sure to get the proper information before attempting it.

Want to learn more about welding, or any of our other steel services? Speak to the pros at Wasatch Steel today.