Why Do My Welds Look Like Popcorn?

Welding can be quite tricky. The littlest mistake can cause the weld to fail or lead to new problems. One problem that most beginner welders face is their welds looking like popcorn. Welding isn’t supposed to pop, so why do my welds look like popcorn? If you’re wondering this, you’re in the right place. You’re not the only one with the problem, and in this article, we’ll explain why your weld might look like popcorn and how you can fix the problem. On that note, let’s dive into it. 

Answer: Why Do My Welds Look Like Popcorn?

There are many reasons why your weld might come off looking like popcorn. It could be because your wire is speeding too fast or too slow during welding. The fire feeding could also happen before the melting, leading the weld to look like popcorn. Some new welders also use solid wire without shielding gas, which could result in popping sounds during the welding process, causing the result to look like popcorn.

What Causes Welds to Pop?

The main reason why welds tend to pop is the incorrect speed of the wire. Hold the welder on the material you’re looking to weld to ensure you have the right speed. If you hear a loud pop, the speed is not right, and you need to adjust. However, below are some things that cause your weld to pop beyond the speed.

1. The Wire’s Type and Diameter: The wrong wire will make your weld pop. Therefore, you must choose the right wire and diameter for your weld. You’ll need to work with solid or flux core wires when welding. Flux wires are ideal if you want more amperage and large diameters. You’ll also need to determine the right speed for the wire you’re using. 
2. The thickness of the Material: For a thin material, you’ll need more inches per minute. The faster the speed, the more quickly the weld penetrates the material. However, it’s different for thick surfaces, so you need to know which speed works for your material. The amperage also depends on the material’s thickness, and so does the speed.
3. Amperage and Voltage: Amperage is the most important fact to consider and could cause your weld to pop if you don’t have the right setting. The wrong amperage would cause your wire to melt faster and burn hotter than necessary.

How to Fix Weld Popping?

Now that you know what causes your weld to pop, below are some ways you can fix weld popping.

1. Adjust Your Wire Speed and the Gun’s Tip: The speed is one of the reasons welds look like popcorn. Therefore, you should always check the speed first. Adjust the speed until you have a constant buzz while working your weld. You should also check the tip of your welding gun and clean it of any splatter or dirt covering it up.
2. Check the Amperage Setting: you should also double-check your amperage setting. It should always increase proportionately to the thickness of the metal you’re working with.
3. Get the Right Wire Size: Ensure your wire isn’t rusty, especially if it has access to moisture. You should also ensure you use the right wire size in your welder to prevent weld popping.
4. Check the Liners: Ensure you check the liner leading to your cable. The liner protects the wire, so check periodically if it is clogged with dirt. Dirt can cause the wires to stick and make your welds pop, so replace the liners with new ones if they’re filled with dirt. 

Final Thoughts

When most people start welding, they can’t determine the right parameters to ensure their welds come out smooth. You might wonder why your welds look like popcorn in such a case. However, you now know why your weld looks like popcorn and how you can fix the issue in the future. If you follow the tips in this article, your welds will have a cleaner appearance.