Welding Knowledge and Advice

28 guides

Every guide in this pillar

28 guides 4 sections

How to Choose a Welding Consumables Supplier How to choose a welding consumables supplier: what to expect, the value of technical support, what to ask before buying, and why a long-term relationship pays. Welding Consumable Recommendations by Industry Welding consumable recommendations by industry for fabrication, manufacturing, engineering, automotive, agricultural and maintenance work, grounded in proven products. Welding Helmets, Gloves & PPE Buying Guide Which welding helmet, gloves and PPE should you buy? Auto-darkening helmets, process-matched gloves, flame-resistant jackets and essential workshop safety kit.

02 Welding Defects & Troubleshooting: The Complete Guide 15

Arc, Gas and Weld Consistency Problems Fix an unstable welding arc, arc-start failures, incorrect shielding gas flow and inconsistent welds: settings, connections, consumables and gas checks. Lack of Fusion and Lack of Penetration What lack of fusion and lack of penetration are, what causes them, and how to prevent them: current, travel speed, torch angle, joint prep and penetration tips. MIG and TIG Filler Wire Comparisons Compare MIG and TIG filler wires: ER70S-6 vs ER70S-3, 308L vs 316L, 4043 vs 5356, copper-coated vs copper-free and wire diameters. Choose the right wire. MIG Burn Back and Contact Tip Problems What causes burn back in MIG welding and how to stop it: wire feed speed, voltage, stick-out and worn contact tips, plus why contact tips burn out. MIG Welding Defects & Troubleshooting Diagnose and fix common MIG welding faults: porosity, spatter, bird nesting, burn back, lack of fusion, undercut, distortion, cracking and poor wire feeding. MIG Wire Feeding Problems and Bird Nesting Fix MIG wire feeding faults such as bird nesting, wire not feeding, inconsistent feed and wire slipping. Liner, drive roller, contact tip and tension checks. MMA Electrode Comparisons Compare MMA stick electrodes: 6013 vs 7018, 6010 vs 6011, rutile vs basic, cellulosic vs low-hydrogen, and AC vs DC MMA welding. Pick the right electrode. Stainless Steel Grade Comparisons Compare stainless steel grades for welding: 304 vs 316, 304L vs 304, and 316 vs duplex. Understand corrosion resistance, carbon content and where each is used. TIG Welding Defects: Porosity, Cracking and Arc Wander Diagnose and fix common TIG welding defects (porosity, weld cracking and arc wander) with their causes and practical prevention from Weldability SIF. Undercut, Overlap and Weld Profile Defects What undercut and overlap are, what causes them and how to stop them, with welding current, travel speed and torch angle fixes for a strong, clean weld profile. Weld Cracking: Causes and Prevention Identify and prevent weld cracking: hot, cold and hydrogen cracking, stainless and aluminium cracking, filler metal choice, preheating and crack repair. Weld Porosity: Causes and Prevention Why welds go porous and how to stop it: contamination, shielding gas, damp wire, wind and end-crater porosity in MIG and TIG, plus how to repair porous welds. Weld Spatter: Causes and How to Reduce It Why MIG welding spatters and how to reduce it: voltage, wire feed, stick-out, shielding gas and wire quality. Which welding wire produces the least spatter. Welding Process and Equipment Comparisons Compare welding processes and equipment: MIG vs TIG, flux-cored vs MIG, laser welding, torches, machines and consumable hardware. Choose the right setup. Welding Shielding Gas Comparisons Compare welding shielding gases: Argon vs CO₂, Argon/CO₂ mix vs pure CO₂, 95/5 vs 98/2, pure Argon vs Argon mix, and helium vs Argon for TIG welding.

03 Welding Safety: The Complete Guide to Hazards, Fume Control and Compliance 4

Fire Safety and Hot Work During Welding How to manage fire risk during welding: keeping the work area clear, fire protection equipment, hot work permits and the role of welder safety training. The Main Hazards of Welding and How to Control Them The main hazards of welding explained: burns, arc eye, UV and infrared radiation, noise, electric shock and hot metal, plus how to control each risk. Welding PPE: Helmets, Gloves, Eye Protection and RPE A practical guide to welding PPE: helmets and auto-darkening lenses, gloves, eye protection, clothing, footwear and respiratory protection (RPE and PAPR). Welding Regulations: COSHH, HSE and Employer Duties Welding safety regulations explained: COSHH and COSHH assessments, HSE duties, occupational hygiene, who is responsible and the records employers must keep.

04 Welding Standards & Compliance: The Complete Guide 6

Consumable Certification & Traceability EN 10204 material certificates explained (2.1, 2.2, 3.1 and 3.2), plus consumable certification, batch traceability and why they matter. Fabrication Certification: EN 1090, CE/UKCA & ISO 3834 How structural steel fabricators meet EN 1090, apply CE or UKCA marking, and use ISO 3834 to demonstrate welding quality management. Key Welding Standards Explained A plain-English guide to the key welding standards (ISO 9606, ISO 15614, ISO 3834, EN 1090, EN 10204 and ISO 5817) and what each one covers. Weld Inspection & Acceptance Criteria Weld inspection explained: visual inspection, NDT methods (UT, RT, PT, MPI), ISO 5817 quality levels, acceptance criteria and common weld defects. Welder & Welding Procedure Qualification WPS, PQR and WPQR explained, plus welder qualification, ISO 9606, ISO 15614 and the role of the welding coordinator under ISO 14731. Welding Documentation & Quality Systems What welding documentation is required, plus quality assurance, audits, calibration, welding symbols and why each supports compliance.

Related in the Knowledge Centre

The complete written guide In-depth reference welding knowledge and advice

Practical, no-nonsense welding guidance that applies across every process and product. This is the cross-cutting advice layer of our knowledge centre, covering welding safety, standards and compliance, defect troubleshooting, and buying decisions. It sits alongside our product guides on consumables, machines and fume extraction.

Welding Safety

How to weld safely and stay compliant: the main hazards and how to control them, PPE, fire and hot-work precautions, and your duties under COSHH and HSE guidance. Start at the Welding Safety hub.

Welding Standards & Compliance

The standards, certification and documentation that underpin quality welding: key welding standards, fabrication certification (EN 1090, ISO 3834), consumable traceability, weld inspection and welder/procedure qualification. Start at the Standards & Compliance hub.

Welding Defects & Troubleshooting

Diagnose and prevent the faults that cost you time and rework: porosity, cracking, spatter, lack of fusion, undercut, and wire-feeding and contact-tip problems, plus consumable and process comparisons. Start at the Defects & Troubleshooting hub.

Buying & Supplier Advice

Make better purchasing decisions: how to choose a welding consumables supplier, PPE buying guidance, and consumable recommendations by industry. Start at the Buying & Supplier Advice hub.

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