What is a common result of welding at incorrect amperage levels?

Welding at incorrect amperage levels can lead to inconsistent bead quality and potential defects. When the amperage is set too low, the weld may not penetrate adequately into the base materials, resulting in weak joints and incomplete fusion. Conversely, if the amperage is set too high, it can cause excessive heat input, leading to burn-through, warping, or other distortions in the material. This imbalance can manifest as irregular bead widths, uneven surface finishes, and increased likelihood of porosity or slag inclusions, which ultimately compromise the integrity of the weld. Maintaining the correct amperage is crucial to achieving a stable arc and uniform bead characteristics, which are essential for quality welding outcomes.