How To Repair a MIG Welder

MIG – Metal Inert Gas Welders are impressive equipment that is simple to use for joining two pieces of metal together by melding them with high-temperature electricity. MIG welder is easier to use in comparison to other welders. Thus you can easily strike and arc metals with this tool. Welding is done by pushing out oxygen with the aid of carbon and argon shielding gas around welding area.

Sometimes you may witness that your tool may not be in working order despite of proper maintenance of MIG welder and there can be several common reasons for this malfunction.

Thus it is important to have knowledge of troubleshooting so by following some simple tips. You would be able to detect problem area on your own and will be able to solve the problem without calling a professional repair technician.

Important tips to follow for proper use:

Before welding any metal, you must clean your equipment along with the metal to be welded. A dirty equipment and metal work piece can affect the performance of your equipment and may even be the cause of a malfunction.

Cleaning would enable you to make it certain that the tool is in working condition and that it would weld properly. A small size wire brush can be used for removal of carbon buildup on torch head whereas, for your metal cleaning, you can use a steel wool or a wire brush.

Contamination can be a result of improper shielding gas used with your welding application. The area to be weld must be surrounded well by inert gas. This practice keeps the risk of contamination reduced.

When dealing with aluminum for welding, you should use pure argon gas whereas for steel, carbon dioxide and argon mixture would do well. You may experience pores in weld bead with the use of improper shielding gas.

Poor quality of material may be responsible for a joint failure. Make sure that the material you are using is a high-quality metal in order to make perfect joints for your projects.

Some Common Problems and Repair Tips:

If you are experiencing difficulty with arc control:

If you are unable to control arc well, welding would not be perfect and you may make some burning holes in your metal piece to be welded. Also, you may experience weld seeping through the joint. In order to cope with this problem, you must lower voltage/amperage of your MIG welder. This holds true even if you are making wide welds and you should also try decreasing feed speed for your welder to cope up with this problem.

If you are unable to make a connection between joints and an arc is not forming, the problem may be that your weld bead is sunk or weld is quite thin. You should increase voltage/amperage and the feed speed of your MIG welder.

Voltage and speed levels of MIG Welders are key features and must be set properly according to the type of metal used for welding and depending upon how thick the weld is?

If you are not able to make an arc with MIG welder:

If you cannot make an arc with welder and you find that the air is flowing properly and the LED output lights are also on, you would need to check torch consumables.

Consumables must be clean and should be tightened properly.Keep a track of high frequency at gap and that the shielding gas engages properly. If you are making arc but it sputters, you may need to check air flow or may need to switch air with bottled one or nitrogen.

If The light of Welder torch doesn’t light:

If welder torch light doesn’t light but machine LED is working, you should check safety LED. If the safety LED is lit, check by resetting the safety button. Also check air flow as if there is no or low air flow the equipment would not start. Turn on the air flow by putting your machine in purge mode.

A minimum of 60 psi must be set on he regulator. Make sure that the pressure is raised slowly to a point where LED lights will light. If you have reached 75 psi and still it is not lighting, there may be some leakage or blockage of air filters.

If LED light is blinking:

If LED light is blinking, this indicates that your MIG welder is overheated and you must let it cool down. Reset it then. Make sure that air flow is never blocked. If both air and fault lights are fluctuating, there may be some problem with your control PC board and you may need to replace it.

If fault and output LEDs are blinking, the arc duty cycle may be exceeded and your machine needs some time to cool down. These lights will stop to blink in 25-30 seconds.

If the welder is not feeding wire properly:

A welder wire not being fed properly, there could be two reasons behind it. Slag may have built up on the contact tip of your welder or tension spring of wire feed may be loose.This problem could be handled by unscrewing the tip of the gun.

It is important because without unscrewing you wouldn’t able to make out if the tip is clogged or not. You can clean or replace tips as these are not expensive parts. Now pull the wire and screw up the tip on its position. Check if the wire is fed properly.

If the problem exists, check tension spring. Welder includes a wing nut holding arm down and squeezing welding wire. The welding wire is held between lower and upper metal wheel. Lower one should be under powered and now tighten nut slightly.

Make sure it is only slightly tightened and not too tight as increased tension can damage the wire. Now activate the trigger and check if the problem is solved paying attention to lower feed wheel.

If the wheel is not moving, remove tension and repeat step again. If still, it doesn’t work, there may be some problem with your motor or circuit board. For that, you need to call a technician for repair or replacement. The motor repair must not be done at home.

If the welding wire is stuck in the gun:

This is one of the most commonly witnessed issues with this equipment. The welding wire stuck in the gun. For repairing this issue, you would need to remove the wire or it could even damage your welding gun. Turn the welder off and take hold of the stock wire and pull it gently from the point it is entering gun.

Check wire roll and repair any bends and twists. There may be rust so you would need to clean it up. Any part that is damaged must be removed with the wire cutter. Once done, you can now get back to using your MIG welder again for welding with repaired wire roll.


MIG welders are the electrical instrument and thus these would also come across with some mechanical problems too. It needs to take proper care   of your tool.  You should know the basic repair methods so that you don’t waste time and money every time your welder gives you a minor malfunctioning.

Although there may be problems that cannot be repaired at home and for those you must call a technician. Following these tips with your selected MIG welder would give you a successful hassle-free welding always.

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