When porosity problems occur, most people immediately suspect a problem with their wire. But this is not always the case. It is important to check the entire system for problems before assuming that switching to a different spool or even a different type of wire is the answer. Here are a few other areas to check:

1.      If a bulk gas system is used, does the problem occur at multiple stations? If so, the delivery system could be suspect. 

2.      If cylinders are used, does the problem occur at multiple stations or is it isolated? If multiple stations are involved, inspect one or two regulators to verify that they are working properly. If that checks out, what is the flow rate set at? Excessive flow rate can cause this problem. For most applications, flow rates should range between 35-45cfh. If the shielding gas is CO₂, is frost building up on the regulator?

3.      Is the gas hose from the cylinder to the solenoid one hose or sections of hose that have been spliced? Inspect for cuts, holes or leaks with soapy water.

4.      Check the gas solenoid for proper operation and/or leaks.

5.      Is the gas line from the solenoid to the torch block leaking? Are the connections tight?

6.      If there is a gas line inside the torch, check it for leaks from loose connections and/or pinholes.

7.      Does the torch have a puncture or slice in it?

8.      Is the gas diffuser clogged with tip dip or anti-spatter spray? If so, this could be the culprit.

9.      Is the nozzle opening restricted with spatter or is there an excessive amount of tip dip or anti-spatter spray?

10.  What is the relationship of the contact tip to the end of the nozzle? The contact tip should not extend beyond the nozzle. If it does, replace it and/or the nozzle to achieve a recess of 1/16” to 3/8”.

11.  Verify that the tip-to-work distance isn’t excessive. Usually, for up to 1/16” wires, the tip-to-work distance should be 1/2” to 1-1/4” maximum.

12.  If the climate is warm, are a lot of fans used in the shop? This could be a contributing factor to porosity. If the doors are left open, how much airflow is moving around the weld areas?

13.  Is the wire stored in a dry place? Are packages torn open and wire exposed?

14.  How often is the spool or coil on the welder before it consumed? Is the wire exposed to too much air or moisture?