Welding Solutions

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Troubleshooting Guide for TIG Welding (GTAW)

Turn off the welding machine’s power and disconnect the supply before troubleshooting

Rapid Tungsten Erosion

PROBLEM	RAPID TUNGSTEN EROSION
POSSIBLE CAUSES	CORRECTIVE ACTIONS
Poor gas flow	Check that hoses, valves, and the torch are not restricted or that the tank is not empty. Gas flow should be between 15-20 CFH.
Electrode polarity set to DCEP (Direct Current Electrode Positive)	Switch to DCEN (Direct Current Electrode Negative) except for aluminum.
Incorrect tungsten diameter for amperage	Change tungsten diameter. The commonly used 3/32” tungsten is limited to 235 A. https://www.oxymax.ca/technique/tig_electrode.html
Torch overheating	Air-cooled torches stay quite hot. For water-cooled torches, make sure the circulator is on, there is coolant and flow is present in the return line.
Oxidation of the tungsten electrode during cooling	Maintain a gas flow for 10-15 seconds after the arc extinguishes (POSTPURGE), one second per 10 amps.
Use of gas containing CO2 or oxygen	Use a 100% argon inert gas. Helium or helium/argon mixes can also be used to increase the heat in the arc.
Tungsten melting into the ceramic nozzle (AC)	If using PURE tungsten, use ceriated tungsten, lanthanated tungsten, or a rare earth tungsten like E3.

Tungsten Contamination

PROBLEM	TUNGSTEN CONTAMINATION
POSSIBLE CAUSES	CORRECTIVE ACTIONS
Tungsten melting into the weld pool	– Reduce the welding current, increase tungsten size. – Use ceriated tungsten, lanthanated tungsten or a rare earth tungsten like E3 (AC-DC). Use thoriated tungsten (DC only).
Tungsten contacting the weld pool	Avoid letting the tungsten touch the weld pool. Keep a distance between the plate and tungsten between 1/16” – 1/8”.

Gas Shielding

PROBLEM	GAS SHIELDING
POSSIBLE CAUSES	CORRECTIVE ACTIONS
Inadequate gas flow or wrong gas	Use a 100% argon inert gas. The flow should be set between 15-20CFH. Helium or helium/argon mixes can also be used to increase the heat in the arc.
Nozzle diameter too small	Use a larger ceramic nozzle or better yet, use a gas lens type nozzle for a more laminar gas flow.

High-frequency present but the arc doesn’t establish

PROBLEM	HIGH-FREQUENCY PRESENT BUT THE ARC DOESN’T ESTABLISH
POSSIBLE CAUSES	CORRECTIVE ACTIONS
Grounding issues	Make sure the work clamp is connected to a clean part of the metal being welded or the welding table.
Torch lead issues	Check for cuts, wear, or crushing damage on the lead. Ensure all connections are tight.
Power source problems	Consult the manufacturer’s manual or a technician for power source troubleshooting.

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