What can result from current setting being too low in SMAW?

When the current setting in Shielded Metal Arc Welding (SMAW) is too low, one of the primary issues that can arise is lack of penetration. Penetration refers to the depth that the molten weld metal penetrates into the base material. A low current will not generate sufficient heat to melt the base metal adequately, which means the weld may sit on top of the material rather than penetrating into it. This can lead to weak joints that are more susceptible to failure.

In situations where the current is appropriately set, the heat created by the arc allows for effective melting of both the electrode and the base metal, thus creating a strong fusion. When the current is inadequate, the resulting weld may appear visually acceptable on the surface but lacks the necessary bonding strength beneath.

This phenomenon can also lead to other problems, such as poor arc stability and increased risk of defects, but the most significant and direct consequence of a low current setting is the insufficient penetration of the weld, which undermines the integrity of the welded joint.