Welding Reference Card
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BuyWire Feed Speed Troubleshooting
Burnback, birdnesting, inconsistent feed, and WFS-to-amperage mismatch on MIG/FCAW
Convert wire feed speed to welding amperage with the Wire Feed Speed to Amps Calculator. Browse welding tools on the Welding Hub.
Wire Feed Speed Problems Quick Answer
Use this when the wire stubs, balls at the tip, nests in the drive, or the arc sounds wrong despite "correct" settings on the panel.
| Symptom | What it usually means | First fix | Next tool |
|---|---|---|---|
| Wire fuses to tip (burnback) | WFS too low or stick-out too long | Raise WFS or shorten stick-out | WFS to Amps Calculator |
| Stubbing / arc cuts out | WFS too high for voltage | Lower WFS or raise voltage | WFS to Amps Calculator |
| Birdnest at drive rolls | Tip blocked or liner kinked | Replace tip; check liner path | Welding Hub |
| Surging arc, uneven bead | Drive tension or liner wear | Tune roll tension; replace liner | WFS to Amps Calculator |
Diagnose in 60 seconds: (1) Burnback or stubbing? (2) Nest at drive or at tip? (3) Tension slip on rolls? (4) WFS/amperage reconcile on calculator?
1. Burnback & Stubbing
What it looks like: Wire welds itself to the contact tip (burnback), or the arc repeatedly extinguishes with a short stub (stubbing). Spatter balls on the tip.
Likely causes: Burnback: WFS too low for heat input, excessive stick-out, or pause at end of weld without crater fill. Stubbing: WFS too high for voltage — wire drives into the puddle faster than it melts.
Fixes: Balance WFS and voltage using the WFS to Amps Calculator; shorten stick-out; use crater fill/run-off tab. Match process to wire diameter and gas.
2. Birdnesting at the Drive Rolls
What it looks like: Wire bundles up at the drive rolls when the tip blocks; motor runs, wire doesn't advance. Often accompanied by a kinked liner or wrong tip size.
Likely causes: Blocked contact tip (spatter, burnback), liner too large/small for wire, sharp bend in torch cable, or drive tension too high crushing soft wire.
Fixes: Replace tip; trim liner; use correct roll groove; relieve cable bend radius. Lower tension until wire slips slightly under hand pull test, then tighten incrementally.
Trap: Fixing birdnest by cranking tension damages liner and motor — clear the blockage first.
3. Inconsistent WFS From Liner & Drive Roll Tension
What it looks like: Arc surges and drops, bead width varies, WFS meter jumps if equipped. "Random" quality on long gun runs.
Likely causes: Worn liner, partial clog, drive rolls worn or wrong size, tension too low (slip) or too high (deformation). Cable overheated and liner swelled.
Fixes: Replace liner on schedule (wire pounds through liner); clean rolls; set tension per manufacturer. For aluminum, U-groove rolls and Teflon liner — standard steel setup causes slip.
4. WFS-to-Amperage Mismatch Symptoms
What it looks like: Panel says 300 IPM but weld looks like 200 IPM heat; ammeter (if used) doesn't match calculator; different reels same setting feel different.
Likely causes: Slip not visible on meter; wire diameter wrong (0.035 setting on 0.030 wire); voltage drop in long leads affecting arc balance; metric/IPM display confusion.
Amps ≈ f(WFS, wire dia, process) — verify with calculator, not panel alone.
Fixes: Enter actual wire size and WFS in the Wire Feed Speed to Amps Calculator; verify drive roll size matches wire; measure stick-out consistently.
Reconcile WFS, Voltage, and Amperage
Most feed problems are mechanical (liner, tip, tension) or WFS/V balance — use the calculator to confirm amperage matches intent.
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Frequently Asked Questions
Burnback vs stubbing?
Burnback fuses wire to tip (often low WFS/long stick-out). Stubbing is wire jamming into cold puddle (often high WFS/low voltage).
Why birdnest at the drive?
Tip blocked — wire can't exit, motor keeps feeding. Clear tip/liner, don't just increase tension.
How tight should drive rolls be?
Tight enough to feed without slip; loose enough that wire doesn't deform — hand-pull slip test.
Does wire diameter affect WFS reading?
Yes — same IPM on wrong diameter gives wrong amperage. Match rolls, tip, and calculator input.