As the premier maintenance and repair company in the business, we've solved almost any welding problem you can imagine! For your convenience, we've collected ten of the most common maintenance and repair welding problems we encounter and their solutions below.

We'd love to help you solve your joining or cladding problem! If you can't find your solution below, contact your local Rockmount/Nassau Sales Professional, or call 1-800-ARC RODS for a return call from one of our Technical Advisors.

Joining unknown or dissimilar steels Cracks in the center of the root pass When changing from stick electrode to MIG wire on the same alloys, cracking problems develop Poor penetration on copper alloys Welds "peel off" when using high strength filler rod Problems welding contaminated cast aluminum Cracking problems on brazed joints subject to vibration (such as exhaust systems) Warpage and distortion when welding stainless steel Cracking and porosity when welding cast iron Problems with inconsistent hard facing performance

Joining unknown or dissimilar steels. [back to top]

Solutions:

• Use welding alloys made just for this situation, such as Rockmount/Nassau Brutus A or Brutus AAA.

Cracks in the center of the root pass. [back to top]

Solutions:

• Use a stronger filler metal, such as Polaris A, Polaris AAA, Brutus A or Brutus AAA.
• Create a larger root pass.
• Use more pre-heat.

When changing from stick electrode to MIG wire on the same alloys, cracking problems develop. [back to top]

Solutions:

• Use a stronger filler metal, such as Polaris MIG.
• Skip weld.
• Slow the welding process down.

Poor penetration on copper alloys. [back to top]

Solutions:

• Use much more preheat.
• Use a higher quality filler metal, such as Venus A, Venus B, or Venus C.
• Slow the welding process down.

Welds "peel off" when using high strength filler rod. [back to top]

Solutions:

• Clean or grind off old filler material.
• Keep inter-pass temperatures below 400 degrees F.
• Use high quality filler material such as Apollo A, Apollo B, Brutus A or Brutus AAA.

Problems welding contaminated cast aluminum. [back to top]

Solutions:

• Clean as thoroughly as possible.
• Use high-quality stick electrodes which will work better because of the flux. (Neptune A, Neptune AAA).

Cracking problems on brazed joints subject to vibration (such as exhaust systems). [back to top]

Solutions:

• Clean as thoroughly as possible.
• Use a flux made specifically to clean. (Brutus Flux)
• Use high quality, high strength brazing alloy such as Brutus G.

Warpage and distortion when welding stainless steel. [back to top]

Solutions:

• Use more clamps and tack welds.
• Skip weld.
• Use high quality, low amperage filler material, such as Gemini A, Gemini B, Gemini BBB or Gemini E.

Cracking and porosity when welding cast iron. [back to top]

Solutions:

• Use stick electrodes that have fluxes specifically designed to clean, such as Rockmount/Nassau's Jupiter A and Jupiter AAA.
• Use high quality, filler material that combines high strength and elongation, such as Jupiter B, or Jupiter BBB.

Problems with inconsistent hard facing performance. [back to top]

Solutions:

• Use hard facing alloys specifically designed for your application, such as Rockmount/Nassau's Apollo A, Olympia A, or Zeta B.
• Consult a trained Rockmount/Nassau sales professional for help in selecting the right alloy and for instruction In how to apply it.