What are the consequences of using improper welding parameters?

Using improper welding parameters can significantly increase the risk of welding defects and compromise joint integrity. Welding parameters such as voltage, amperage, travel speed, and gas flow rates are carefully calibrated to ensure that the weld achieves the desired strength, appearance, and metallurgical properties. When these parameters are not set correctly, it can lead to a variety of issues, including inadequate penetration, excessive spatter, porosity, and cracking. These defects not only affect the structural integrity of the weld but may also result in premature failure of the welded joint under stress or load. Therefore, maintaining proper welding parameters is critical for ensuring the reliability and safety of welded structures.