Why Is My Mig Welder Popping & How To Fix It 2021

MIG welding is a universal process because of its cost-effectiveness, quick learning process, and speed. With dual voltage mig welder, you can easily handle all the larger projects with efficiency. With all these benefits, you may face some unexpected challenges as well.

One of them is the popping of MIG welders. At the time of welding, MIG welders often started popping. This issue can arise due to so many factors. In this article, I will show the reasons for Why is my mig welder popping?

Why Is My Mig Welder Popping?

There are some obvious reasons behind Why is My Mig Welder Popping? MIG welders can create pop with improper wire settings like too fast or too slower wire speed. This is the main cause of welding popping. Always listen to the sound while welding with MIG carefully. Also, see the welding marks; it will solve half of the problem.

Why Is My Mig Welder Popping

A well adjusted and good dual voltage mig welder will sound like frying bacon strips or sizzle like sounds. Also, the welding finish will be even and full. Another fact is, many people mistakenly or intentionally avoid using a shielding gas. As a result, it causes so much popping and hissing. If you keep a long distance between the electrode and the contact tip, popping can happen.

Flux core wire and solid core wire do not work well at the same level of speed. Even the aluminum sheet and stainless-steel show different results with the same IPM. Thus, it causes popping. Improper amperage burns the wire and causes welder popping.

How to Stop a Mig Welder from Popping?

Follow the below steps to stop the MIG welder from popping.

How to Stop a Mig Welder from Popping

Set the Wire Speed:

To set the wire speed properly, you can do one thing. Take a piece of metal and up to it, hold the welder, and start welding. If it pushes back the gun and makes a loud popping noise, that means the wire is not set properly. Adjust the wire speed up and down until you get the perfect sound and weld.

Check the Tip:

Properly check the welding gun tip. Many times, it can get clogged with dirt, splatter, and burn back into the tip. It makes the welding wire stick. In this case, simply replace the old tip with a new one.

Wire Size:

Always make sure to use the right welding wire size. To weld 22 to 18 gauge, you need 0.23 welding wire. For welding 22 gauge to 1/8 inch, you need 0.30 welding wire. Also, you will need 0.35 welding wire to weld between 18 gauge to 1/4-inch material.

Rusty Wire:

If you keep the welder machine open in the garage or shop, it may start to rust. Especially with a lot of moisture, it can cause. Rusty wire makes the wire sticky while welding and can give a jerking motion. It is the main cause of pop. Replace the rusty wire with a fresh wire role. To protect the wire from dirt and rust keep in mind to put a towel on top of the wire after using.

Set the Amperage:

To avoid popping with the welder, correctly set the amperage. Otherwise, it can burn the wire or make it too cold. To figure out the actual running amperage, take the metal’s thickness and multiply it by 1000. If you are going to weld a 1/8″ metal, you should multiply it 1000. For example, the decimal format of 1/8″ is 0.125; multiply it by 0.125 times 1000. That means you can set the amperage at 125 amps.


Accurately inspect the liner in the welder lead. Inside the welding gun, there is a liner that is used for protecting the wire. This liner gets plugged very often due to welding wires dirt. When the liner gets plugged, the welder starts to pop. Solve this issue by removing the liner and placing a new liner.

Material Thickness:

The thickness of the material matters the most while welding. You have to run the welder machine at a higher inch per minute while welding a 1/8″ metal sheet. On the other side, with thicker metal, you need slower IPM. If you go too slow, the welder will pop. When you go too fast, also the welder will pop.

Frequently Asked Questions

This section will give you more clarification about Mig welding. Have a look and learn about this welding process.

Is Mig Welding Dangerous?

The main risks of MIG welding are welding fumes, arc radiation, electrical, inert gas, fire, noise, heat, etc. MIG welding can be dangerous if you don’t take safety precautions.

Can You Weld With a Mig Welder Without Gas?

Yes, you can weld a MIG welder without gas but in windy conditions. A no gas MIG welder uses flux, and this flux is the main reason for dirtier welding. So, make sure to properly clean the metal before welding with no gas.

Do You Push or Pull a Mig Welder?

You can do push or pull with a MIG welder. You just have to push the welding gun forward and pull the welding gun backward. For the push and pull method, aim the travel angle between the welding gun and the surface at 5 to 15 degrees. It can decrease splatter and reduce accuracy.

Can a Mig Welder Electrocute You?

Yes, it can electrocute you. Occasionally it can give a mild shock. The number of injuries or fatal shock cases is very rare. Although, they make sure that you never feel any kind of shock.

Bottom Line

So, these are the reasons why my mig welder popping. Beginners need more practice to learn these processes and get used to welding with MIG welders perfectly. Follow the chart or guide provided by the manufacturer. Try to adjust the speeds by minor changes until things get entirely settled.

MIG welding is the easiest and flexible process of welding. By learning the process and following the basic things, anyone can do it. Make sure to wear all the safety measures while before performing the welding process.


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