Improving Welds and Output: A Guide for Small Businesses and Workshops

Bright sparks erupt in front of a welder wearing a welding mask, apron, and gloves

Welding is a critical process for many small businesses and workshops. In this article, we’ll provide an overview of how you can improve your welds and your output.

Why quality welding is important for small businesses and workshops

Poorly welded joints can lead to losses, a decrease in repeat customers, bad word of mouth, and not meeting industry standards. In addition, substandard work can lead to accidents and structural failure. In contrast, quality welds hold up well, keeping customers safe and giving them peace of mind. Quality output increases the longevity of the products produced, and it helps you avoid litigation from accidents and structural failure.

When choosing a welder, it is important to look for someone with the experience and skills necessary to produce quality work. There are many welding schools across the country that offer certification programs. These programs can give welders the skills they need to produce quality work that meets industry standards. In addition, many businesses now require welders to have certification in order to be hired. As a result, acquiring welding certification can open up new opportunities for employment.

The difference between good and bad welds

Anyone who has ever looked at a welding project knows that there is a big difference between a good weld and a bad weld. A good weld is clean and smooth, with a consistent width and no gaps. In contrast, a bad weld has slag, porosity, or cracking. So, what causes these differences?


Welders often refer to the by-products of the welding process as slag. Slag can be a number of different things, including spatter, flux residue, and metal oxides. Spatter is created when the molten metal from the welding process is ejected from the weld puddle. It is a common problem, but it can be removed by scraping and grinding. Spatter can cause a number of problems, including poor welds, contamination, and safety hazards.

In MIG welding, slag appears as a result of the impurities in the welding rod. The slag is melted and deposited on the weld bead along with the molten metal from the electrode. In TIG welding, slag is created when the tungsten electrode comes into contact with the workpiece. This results in an arc that melts both the tungsten and the metal being welded. Metal oxides are created when oxygen comes into contact with hot metals. These oxides form a thin film on the surface of the weld bead that can cause cracking and other defects in the finished product.


Porosity is a problem that can occur in both MIG and TIG welding. It is caused by the inclusion of gas bubbles in the weld metal. These gas bubbles can be caused by a number of things, including the use of dirty or contaminated equipment, incorrect shielding gas flow, and incorrect welding technique. Porosity makes a weld bad by causing it to be weak and brittle. It also makes the weld difficult to clean and can cause corrosion and other defects in the finished product.

In MIG welding, porosity appears as small black spots on the weld bead. These spots are created when gas bubbles escape from the weld puddle and are subsequently solidified. In TIG welding, porosity appears as small holes or pits in the weld bead. These holes are caused by the inclusion of air pockets in the weld metal. Air pockets can be caused by a number of things, including incorrect tungsten placement, incorrect torch angle, and incorrect filler metal choice.

If you make a porous weld, you may have to scrape or grind it off. To avoid making one in the first place, one way is to use a filler metal that has a low melting point. This will help to solidify the gas bubbles and prevent them from causing further defects in the weld. Another way to fix porosity is to use a flux that is specifically designed for welding aluminum. Aluminum fluxes contain a number of compounds that help to dissolve the gas bubbles and prevent them from causing problems in the weld. Finally, you can use an argon-based shielding gas instead of helium or carbon dioxide. Argon is heavier than these gases and will help to keep the weld puddle from becoming too turbulent. This will reduce the chances of gas bubbles forming in the weld metal.

By understanding the differences between good and bad welds, you can avoid common mistakes and produce high-quality work.

A worker wearing a welding mask and gloves uses a TIG welder on a large sheet of metal

How to improve your welding quality

If you’re serious about welding, then you need to invest in both better equipment and proper training. Family-owned welding businesses have been around for many decades, but lately, the industry has seen a surge in popularity with the rise of do-it-yourself culture and the popularity of shows like Metal Shop Masters. Because of this, there are now more options than ever when it comes to choosing welding equipment. Make sure that you have everything you need for your projects, and avoid taking on projects that you are not equipped for. Invest in weld cleaners and metal marking fluid for cleaner welds and premium-looking output.

When it comes to training, there are also a lot of options available, from online courses to in-person classes. And while it’s true that you can learn a lot from online videos and tutorials, there’s nothing like getting hands-on experience from a qualified instructor. So if you’re serious about welding, be sure to invest in both the right equipment and the right training.

Finally, always make sure to check your output before letting it go out. Do not hesitate to hold something back and make your welders redo it if it’s not right. Even if they were the ones who did it, it’s your name on the line. You must take responsibility for it as well.


Welding can be quite complex, and there are a number of things that can go wrong. By understanding the differences between good and bad welds, you can avoid common mistakes and produce high-quality work. To improve your welding quality, you should invest in both better equipment and proper training. We hope that we can help your business live up to its potential!


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