A welder is performing FCAW-G on an outside corner joint in the flat position. They notice that the weld bead is very convex with poor tie-in at the toes and excessive slag inclusion. The wire feed speed and voltage are set according to manufacturer specifications. What is the most likely issue?

Question: A welder is performing FCAW-G on an outside corner joint in the flat position. They notice that the weld bead is very convex with poor tie-in at the toes and excessive slag inclusion. The wire feed speed and voltage are set according to manufacturer specifications. What is the most likely issue?

Answer options:

• The shielding gas flow rate is too low ✅ The travel speed is too fast
• The electrode stick-out is too short
• The polarity is set to DC Electrode Negative (DCEN)

Correct answer: The travel speed is too fast

Explanation: A travel speed that is too fast with FCAW-G will result in a narrow, convex bead with poor wetting out at the toes and potential slag inclusions because the molten puddle doesn't have enough time to properly form and flow. Short stick-out typically increases penetration, and gas flow issues usually cause porosity, not typically a convex bead with poor tie-in.