Posted on October-10-2025
Welding looks easy when you’re watching someone else do it, but anyone who’s picked up a torch knows it’s not that simple. One small slip-up and suddenly you’re dealing with one of those classic welding mistakes messy beads, weak joints, or metal that just won’t hold. Whether you’re just getting started or been at it for years, it’s worth knowing the usual welding mistakes most people make and how to steer clear of them.
You’d be surprised how many people don’t bother cleaning their steel before welding. Bit of rust, oil or paint might not look like much, but it’ll mess up your weld faster than you think. You’ll end up with porosity or the weld just won’t bite properly.
How to avoid it:
Give your metal a proper clean. Use a grinder or wire brush and get it shiny. The cleaner it is, the stronger and neater your weld will be.
If you’re using the wrong electrode or filler, you’re asking for trouble. Some rods just don’t suit certain metals or positions, and you’ll get cracking or weak joints.
How to avoid it:
Always check you’re using the right filler for the job. Match it to your base metal and process, don’t just grab whatever’s nearest on the bench.
If your pieces aren’t sitting right, no amount of skill will save it. Gaps, dodgy angles, or bits not lining up can all lead to ugly, weak welds.
How to avoid it:
Take a few extra minutes to set everything up properly. Tack it, check it, and make sure it’s snug before you start.
Speed’s a tricky one. Move too fast and the weld won’t penetrate properly. Go too slow and you’ll get burn-through or a big old lump of metal.
How to avoid it:
Find a rhythm that works for the material. Watch your puddle, it’ll tell you if you’re going too quick or slow.
If your amps or volts are off, you’ll know straight away. Too much power and you’re burning holes. Too little and you’re basically gluing metal together.
How to avoid it:
Start with the settings the manufacturer suggests, then tweak from there. Bit of trial and error’s fine as that’s how you learn.
Angle makes a big difference. Hold it wrong and you’ll get slag all over the place, or the bead will look uneven.
How to avoid it:
Keep your angle steady about 10 -15 degrees is usually spot on. Practise keeping your hand consistent instead of waving it around.
It might seem boring, but it matters. No gloves, no mask, no proper ventilation, you’re just asking to get burnt or breathe in stuff you shouldn’t.
How to avoid it:
Put your gear on. Gloves, helmet, jacket, and make sure the air’s moving. It’s not worth the risk.
Machines need looking after. If your torch is clogged or your cables are knackered, you’ll get bad welds every time.
How to avoid it:
Keep your kit clean. Check leads, change tips, clear the nozzle. Five minutes of maintenance saves a load of frustration later.
Too much heat and you’ll warp or weaken what you’re welding. Not enough and it won’t fuse properly.
How to avoid it:
Adjust your heat depending on the metal. On thinner stuff, short bursts work better. You can always make another pass, but you can’t unburn it.
Just because it looks decent on top doesn’t mean it’s sound underneath. There could be little cracks or bubbles you can’t see.
How to avoid it:
Give your welds a good once-over. If it’s a critical job, do a bend test or a simple inspection. You’ll sleep better knowing it’s solid.
Everyone makes mistakes when welding and that’s how you get better. The trick is noticing what went wrong and sorting it next time. Keep your gear clean, your settings right, and your prep solid, and your welds will come out miles better.
If you think your equipment needs an upgrade to avoid these common mistakes at Arc Welding we supply a range of new and used welding equipment from a variety of manufacturers to help you have the best equipment for your job.
