Why is My MIG Welder Popping and How to Stop It 2021

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When people start to learn to weld, especially MIG, the first thing they encounter is the popping sound while welding. The result of that popping sound isn’t any good; it ends up making a very bad weld between the pieces. With patience and practice, you notice the change in that sound and witness the dramatic change in your welding quality. However, getting that change in action takes time and concentration, and most importantly, the knowledge about MIG welding.

A welded piece should have a joint with a nice looking, relatively flat, and throughout even weld bead. A bad weld will have an uneven weld caused while you hear those pops while welding. So, preventing the popping is the one thing you want to get rid of. Stick to the article if you’re wondering why is my mig welder popping and how do I get rid of it.

Why Is My MIG Welder Popping?

If you’re starting with MIG welding, chances are you’re wondering why is my mig welder popping and making bad joints. Well, the joints don’t stick together because of that sound and weld, and here are the reasons why does it happen:

Why Is My Mig Welder Popping

Wrong wire speed

The most common reason why the MIG welders suffer from the popping is the wrong wire speed. If you’re facing the problem, either you’re feeding the wire too fast or too slow. To test it out, touch the wire to the piece, hold the trigger, and closely hear the sound. If the joint tries to push the gun off or miss an even sound, you know the wire feeding doesn’t have the right speed.

Material thickness

The second most common problem that causes popping in MIG welding is the thickness of the welding material. Welding a 1/8″ sheet metal can get you a higher IPM (Inches per minute) where a thicker metal won’t. As you start to rais the metal’s thickness, the IPM also starts to fall and makes it harder to penetrate the metal. When you have to go slow because of a thicker material, it tends to get you popping sounds.

Wrong Wire sizes

The size of the wire you’re using to weld matters a lot when it comes to the popping problem with MIG welding. A thin wire like a 0.23 electrode will get you a great running speed of about 300 IPM without any problem. On the other hand, a regular 0.35 electrode will get you up to 150 IPM without causing any problem. However, the ideal standard may vary from one manufacturer to another, be sure to check the recommended wire size from yours.

Bad amperage

The amperage is the thing that melts the wire, heats the piece, and joins them together like solid metal. A bad amperage setting will cause a lot of problems, that’s for sure, especially with MIG. You must use the right amperage settings to avoid any popping problem with MIG welding. The right amperage settings will help you avoid the popping, bad, and unstable welding.

Using the wrong type of wire

If you’re using a wrong wire that doesn’t suit the material you’re welding, it will cause different issues, including pop. A flux core welding electrode will give you a completely different welding speed and output than a solid wire. With a solid wire, you’ll use an external gas shield to protect the puddle, which isn’t the same case for flux core wires.

How to Stop a MIG Welder From Popping?

Popping in MIG welding is a common problem that weakens the quality of the weld’s final output. Here are the best hacks to stop a MIG welder from popping and getting the best output from the welding job:

Use the right amperage

Before you start using your MIG welder, setting up the amperage is the utmost important thing for the machine’s best output. The right amperage settings will allow you to avoid overburn or keeping the wire too cold. Decide how much amperage you need and set it accordingly. To figure how much amperage you need, multiply the thickness of the metal by 1000. For example, if you’re welding a mild steel 1/4″ sheet, the multiplication will give you 250 amps as the ideal setting.

Decide the wire speed and size correctly

I mentioned how the wrong wire-speed causes the problem, and now it’s time to correct it. Let’s do it practically in the most illustratable way possible; first, start by selecting the right size. It’s easiest because most of the manufacturers include a size chart in the back of the machine. After getting the size correct, feed the wire, light up the material, and listen to the sound first. Adjust the wire speed higher and lower until you hear a constant buzz without any popping and see how much progress you’re making.

Check the tip, liner, and wire rust

Check the welding gun and see if the tip is in good shape; don’t use if it’s burned back, plugged with splatter, or even off with the dirt. Clean it if possible or change it and move onto the liner if it has any bent or somehow chucking the wire, fix it. The last thing you pay attention to is, whether it’s Gas shielded or flux core, you check for any faults on the wire itself if there is dirt, rust, or other imperfections.

Frequently Asked Questions

Here are the most common and frequently asked questions about MIG welding that you should know about as well:

Is MIG welding strong?

With the right settings and the right welding process, MIG welding is one of the strongest methods ever. It’s a common welder for aluminum, pipe, products, even the aircraft industry!

Is gasless MIG good?

Gasless flux core MIG welding can be a great option for a higher penetration, especially for thinner metals. However, the quality depends on the machine and the welding efficiency.

Can you mig weld without Gas?

Yes, you can use a flux core electrode for MIG welding if your MIG welder is compatible with that. Most of the MIG welders come with dual usage methods to weld both Gas and gasless.

Final Thought

Welding can be fun, and MIG is the best option, especially if you’re a beginner to the game. A bad weld can never get you the satisfaction of accomplishment you want, where the popping problem is keeping you back.

If you’ve been asking why is my mig welder popping and causing weak joints, now you know what to do. By following these steps before you start welding, you will land some rigid joints that soothes your eyes. Turn them into habits, and be sure to check the steps before you start welding with a MIG welder.

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