Despite its ability to produce high-quality welds, TIG welding may encounter issues that prevent it from working properly, even with skilled welders. This welding technique is widely used in industries such as aerospace, automotive, and medical.
In the upcoming sections, we will explore the most frequent issues that may arise during TIG welding and offer solutions to troubleshoot and resolve them. By delving into each problem and solution, we aim to assist you in identifying and fixing any problems that may occur during TIG welding.
Our coverage will encompass issues that pertain to power supply, gas flow, tungsten electrodes, filler metal, and other factors that may impede the proper functioning of TIG welding.
Upon concluding this article, you will possess a more comprehensive comprehension of the typical issues that may arise during TIG welding, as well as the ability to troubleshoot and resolve them.
TIG Welding Troubleshooting Reasons
1. Poor Gas Flow
Maintaining an appropriate gas flow is crucial in TIG welding, as it shields the weld from contamination and oxidation. Inadequate gas flow can result in porosity in the weld, leading to weak joints. To address this problem, it is essential to ensure that the gas cylinder is full and that the gas flow rate is sufficient, typically ranging from 10 to 30 cubic feet per hour (CFH).
2. Contaminated Tungsten Electrode
Tungsten electrodes that are contaminated can result in welding defects such as arc instability and porosity. It is crucial to ensure that the tungsten electrode is free of any dirt, oil, or other contaminants. To sharpen the electrode correctly, use a dedicated tungsten grinder or fine-grit sandpaper.
3. Poor Grounding
An inadequate ground connection can lead to welding defects such as arc instability and insufficient heat. It is essential to ensure that the ground clamp is firmly attached to the workpiece and that the connection is free of any rust or paint.
4. Incorrect Polarity
The type of metal being welded determines whether TIG welding requires direct current (DC) with electrode positive (DCEN) or electrode negative (DCEN) polarity.
Incorrect polarity can result in problems such as inadequate heat, poor penetration, and electrode overheating. Verify the welding machine’s polarity settings and modify them as necessary.
5. Wrong Shielding Gas
Incorrect polarity can result in problems such as inadequate heat, poor penetration, and electrode overheating. Verify the welding machine’s polarity settings and modify them as necessary.
6. Arc Starting Issues
Initiating the arc can be challenging, particularly with thick metals or corroded surfaces. If the arc is unstable or fails to start, consider increasing the amperage, utilizing a higher frequency setting, or employing a scratch-start technique.
7. Welding Technique
To produce high-quality welds using the TIG welding technique, precision and practice are necessary. Common errors include moving the torch too quickly or slowly, holding the torch too close or far from the workpiece, and using the incorrect filler metal. Verify that you are using the appropriate technique for the specific weld and that your weld pool is uniform.
8. Equipment Malfunction
Regular wear and tear, inadequate maintenance, or defective parts can cause TIG welding equipment, such as the welding machine, torch, foot pedal, or cables, to malfunction. It is essential to inspect and maintain your equipment regularly and replace any damaged or worn components.
9. Welding Environment
The TIG welding quality can also be influenced by the welding environment. Welding in a drafty or windy location can cause gas turbulence and impact the shielding gas coverage. Welding in a dusty or humid area can also cause contamination and affect the weld’s quality. It is critical to ensure that the welding environment is free of drafts, clean, and dry.
10. Welding Material Thickness
TIG welding is ideal for welding thin materials, usually ranging from 0.005 to 0.125 inches in thickness. Welding thicker materials may necessitate multiple passes or higher amperage, which can cause distortion and impact the weld’s quality. It is critical to use the appropriate welding technique and equipment for the material thickness.
11. Welding Position
The TIG welding quality can also be influenced by the welding position. Welding in a flat or horizontal position is typically simpler than welding in a vertical or overhead position. Welding in a vertical or overhead position may necessitate higher amperage and slower travel speed to ensure adequate penetration and coverage.
12. Welding Joint Preparation
To ensure proper fit-up and penetration, TIG welding necessitates precise joint preparation. Welding defects can be caused by improper joint preparation, such as insufficient bevels or gaps, which can impact the weld’s quality.
It is crucial to use the appropriate joint preparation technique for the specific weld and ensure that the joint surfaces are free of any contaminants.
13. Welding Filler Metal
The use of an incorrect filler metal can impact the weld’s quality and result in welding defects like porosity, cracking, or lack of fusion. It is essential to use the appropriate filler metal for the specific weld and ensure that it is free of any rust or contaminants.
14. Welding Amperage And Travel Speed
To ensure proper heat input and penetration, TIG welding necessitates precise control of amperage and travel speed. Welding defects can be caused by using too high or too low amperage or travel speed, which can impact the weld’s quality. It is crucial to use the appropriate amperage and travel speed for the specific weld and closely monitor the weld pool.
15. Welding Safety
TIG welding can be hazardous to the welder and others in the vicinity due to high heat and electrical currents. It is essential to use appropriate personal protective equipment, such as gloves, eye protection, and a welding helmet, and follow proper welding safety procedures.
