| Cracks | Excessive number of layers | Check hardness and determine maximum bead count |
| | Incompatibility between base metal and coating | Verify material compatibility |
| | Electrode lifted too quickly | Use proper technique |
| | Casting defects in base metal | Replace base metal |
| | Lamination in base metal | Replace base metal |
| | Excessive stress | Review operating conditions and coating type |
| | Fatigue | Replace base metal or repair |
| Porosity | Insufficient shielding | Change electrode, use windshields |
| | Dirty or contaminated base metal | Clean or replace materials |
| | Inadequate welding technique | Use correct technique |
| | Contaminated filler material | Replace electrode |
| | Excessive arc length | Reduce arc length |
| | Unstable arc | Check causes and solutions |
| Arc ignition problems | | Check causes and solutions |
| | High amperage | Lower amperage |
| Solid Inclusions | Dirty or contaminated base metal | Clean or replace materials |
| | Lack of slag cleaning between passes | Clean slag thoroughly |
| | Slag interference in arc | Replace electrode |
| | Insufficient amperage | Increase amperage |
| | Inadequate welding technique | Use correct technique |
| | Poor joint preparation | Redesign joint |
| Incomplete Fusion | Poor joint preparation | Improve component positioning |
| | Insufficient amperage | Increase amperage |
| | Travel speed too fast | Decrease travel speed |
| Undercutting | Inadequate welding technique | Use correct technique |
| | High amperage | Reduce amperage |
| | Excessive arc length | Reduce arc length |
| | Incorrect electrode diameter vs base metal thickness | Use smaller-diameter electrode |
| | Improper travel speed | Adjust travel speed |
| | Unstable arc | Check connections |
| | Irregular flux | Replace electrode |
| | Inadequate power source | Review machine specs |
| | Improper amperage | Adjust amperage |
| | Welder skill | Verify welder proficiency |
| Difficulty Igniting Arc | Insufficient amperage | Increase amperage |
| | Inadequate power source | Review machine specs |
| | Poor cable connections | Secure all connections properly |
| | Dirty base metal | Clean the base metal |
| Slag Adherence | Incomplete slag removal between passes | Use appropriate cleaning tools |
| | Incorrect joint design | Redesign the joint |
| | High amperage | Lower amperage |
| | Overheating of parts | Allow parts to cool |
| Excessive Spatter | High amperage | Lower amperage |
| | Excessive arc length | Reduce arc length |
| Part Distortion | Component restriction | Modify welding sequence |
| | Overheating | Allow controlled cooling |
| | Incorrect joint design | Redesign the joint |
| Incorrect Bead Shape | Inadequate welding technique | Use proper technique |
| | Poor joint preparation | Improve component layout |
| Arc Interruptions | Incorrect current and polarity | Use correct current and polarity for the electrode |
| | Insufficient OCV or CCV | Use a power source with appropriate capacity |
| | Electrode overheating | Improve striking and re-striking technique |
| | High amperage | Reduce amperage |
| | Lack of clamping | Use tack welds and proper holding tools |
| | Poor joint preparation | Improve component layout |
| Bead Detachment | Excessive number of beads | Verify maximum allowable passes |
| | Inappropriate electrode for wear type | Choose electrode based on wear type and required hardness |
| | Improper heating and cooling | Verify electrode type and required temperatures |
