TECHNICAL

SPECIFICATIONS
FOR TIG WELDING

THE STANDARD
IN TIG WELDING
Form 116–April 2015
THE STANDARD IN TIG WELDING
CK Worldwide, Inc.
TEL: 1-800-426-0877
P.O. www.CKWORLDWIDE.com
Box 1636, Auburn, WA 98071 USA
Phone: 1.800.426.0877
Fax: 1.800.327.5038 Back To Table of Contents www.CKWORLDWIDE.com1
 TABLE OF CONTENTS
TIG TORCH CONNECTION DIAGRAMS
GAS-COOLED TORCHES 3
WATER-COOLED TORCHES 3

CHARACTERISTICS OF CURRENT TYPES FOR TIG WELDING

DC STRAIGHT POLARITY 4
DC REVERSE POLARITY 4
AC HIGH FREQUENCY 4
SELECTING CORRECT TORCH NOZZLE MATERIAL 5
GAS LENS BENEFITS 5

SHIELD GAS SELECTION AND USE

FREE ONLINE TIG GUIDE FOR SHIELD GAS FLOWS, CURRENT

WELDING TRAINING SETTINGS, CUP SELECTION

TUNGSTEN ELECTRODE TIP SHAPES
6

CK Worldwide offers an introduction to AND CURRENT RANGES 6

CORRECT TORCH AND ROD POSITIONING 6
TIG torches, how they are made, and
how to select the right torch for the job.
TUNGSTEN SELECTION AND PREPARATION
Visit www.WELDTRAIN.com
TUNGSTEN TIP PREPERATION 7
TUNGSTEN EXTENSION 7

WeldTRAIN
Online Training for the Welding, Gases, and Safety Industry.
TUNGSTEN GRINDING
COLOR CODE FOR TUNGSTEN ELECTRODES
7
7

Free training - on your own time! TUNGSTEN CHARACTERISTICS AND PENETRATION PROFILES
TUNGSTEN ELECTRODE CHARACTERISTICS 8
FIND US ON: TUNGSTEN ELECTRODE CURRENT RANGES
WELD PENETRATION PROFILES
8
9

TYPICAL MANUAL TIG WELDING PARAMETERS

Product demonstrations, ALUMINUM 10
welding tips and more. TITANIUM 10
MAGNESIUM 10
DEOXIDIZED COPPER 11
FOLLOW US: STAINLESS STEEL
LOW ALLOY STEEL
11
11
TWITTER:
@CKWWInc TROUBLESHOOTING GUIDE FOR TIG WELDING
EXCESSIVE ELECTRODE CONSUMPTION 12
INSTAGRAM: ERRATIC ARC 12
INCLUSION OF TUNGSTEN OR OXIDES IN WELD 12
@ckworldwide POROSITY IN WELD DEPOSIT 12
CRACKING IN WELDS 12
The information in this manual represents the best judgement of CK Worldwide, Inc. and is intended for INADEQUATE SHIELDING 12
use by experienced personnel. Never operate any equipment without carefully reading, understanding,
and following all of the related safety rules and practices. CK Worldwide makes no claims, expressed
ARC BLOW 12
or implied, as to the viability of this information for any application or use. The individual user is solely SHORT PARTS LIFE 12
responsible for any and all uses of the information contained herein, since CK Worldwide has no means
to confirm the correct use of, or control any of the variables to the use of any and all information herein.

Follow us:
2 P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com
connection diagrams

2 Piece gas cooled 1 piece gas cooled

Valve

Valve
Lug

Dinse

Gas In

Gas In

1 piece gas-thru Water cooled gas-thru

Gas In

Dinse
Water Return

Water In

water cooled
NOTE: 1 quart (1 liter) per min. flow rate
Water in through water line
Water out through power cable

Dinse

Water Return

Water In

Gas In

Follow us: Back To Table of Contents

P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com 3
 CHARACTERISTICS OF CURRENT TYPES FOR GAS TUNGSTEN ARC WELDING

When TIG welding, there are three choices of welding current. They are: Direct Current Straight Polarity
(DCSP), Direct Current Reverse Polarity (DCRP), and Alternating Current with or without High Frequency
stabilization (ACHF). Each of these has its applications, advantages, and disadvantages. A look at each
type and its uses will help the operator select the best current type for the job. The type of current used will
have a great effect on the penetration pattern as well as the bead configuration. The diagrams below show
arc characteristics of each current polarity type.

DCEN DCEP AC

TIG welding DCSP TIG welding DCRP TIG welding with ACHF
Direct Current Straight Polarity Direct Current Reverse Polarity Alternating Current High Frequency
produces deep penetration by produces the best cleaning action as combines the weld penetration on the
concentrating heat in the joint area. the argon ions flowing towards the negative half cycle with the cleaning
No cleaning action occurs with this work strike with sufficient force to action of the positive half cycle. High
polarity. break up oxides on the surface. frequency re-establishes the arc which
breaks each half cycle on transformer
based machines.

CURRENT TYPE DCSP CURRENT TYPE DCRP CURRENT TYPE ACHF

ELECTRODE ELECTRODE ELECTRODE
Electrode negative Electrode positive Alternating
POLARITY POLARITY POLARITY
OXIDE CLEANING OXIDE CLEANING OXIDE CLEANING Yes (once every
No Yes
ACTION ACTION ACTION half cycle)
HEAT BALANCE 70% of work end HEAT BALANCE 30% of work end HEAT BALANCE 50% of work end
IN THE ARC 30% at electrode end IN THE ARC 70% at electrode end IN THE ARC 50% at electrode end
PENETRATION PENETRATION PENETRATION
Deep narrow Shallow wide Medium
PROFILE PROFILE PROFILE
ELECTRODE ELECTRODE ELECTRODE
Excellent Poor Good
CAPACITY CAPACITY CAPACITY

DCSP mainly used on: Stainless Steel, Mild Steel, Nickel, Copper, Titanium
ACHF mainly used on: Aluminum, Magnesium
DCRP mainly used on: Thin Material

Follow us: Back To Table of Contents

4 P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com

 selecting the correct torch nozzle material

CUP CHART

ALUMINA CERAMIC SUPER CUP PYREX

High impact resistance High thermal shock High thermal shock High visibility
Low thermal shock Low impact resistance High impact resistance Low thermal shock
(Aluminum Oxide) (Lava) (Silicon Nitride) Low impact resistance
(Pyrex)

Exit diameter measured in Designed to fit

1/16” (1.6mm) increments GTAW torches

gas lens benefits

• 40% Argon savings

• Columnar flow gas pattern

Standard Gas Saver
Collet Collet
• Longer electrode stick-out
& Collet & Collet
Body Body • Lower gas flow rates

• Better visibility

Turbulent gas Columnar gas • Longer parts life

flow pattern flow pattern

• Cleaner welds

Follow us: Back To Table of Contents

P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com 5
 GUIDE FOR SHIELD GAS FLOWS, CURRENT SETTINGS & CUP SELECTION
WELDING CURRENT (AMPS) TUNGSTEN TYPE ARGON FLOW FERROUS METALS ARGON FLOW ALUMINUM
Electrode AC AC DCSP DCSP Standard Body Gas Lens Body Standard Body Gas Lens Body
Diameter Cup Size Pure Thoriated Pure Thoriated CFH (L/MN) CFH (L/MN) CFH (L/MN) CFH (L/MN)
.020" 5-8 (3-4)
3, 4, or 5 5–15 5– 20 5–15 5–20 5-8 (3-4) 5-8 (3-4) 5-8 (3-4)
(0.5mm)
.040" 5-10 (3-5)
4 or 5 10–60 15– 80 15–70 20–80 5-10 (3-5) 5-8 (3-4) 5-12 (3-6)
(1.0mm)
1/16" 7-12 (4-6)
4, 5, or 6 50–100 70– 150 70–130 80–150 7-12 (4-6) 5-10 (3-5) 8-15 (4-7)
(1.6mm)
3/32" 10-15 (5-7)
6, 7, or 8 100–160 140–235 150–220 150–250 10-15 (5-7) 8-10 (4-5) 10-20 (5-10)
(2.4mm)
1/8" 7, 8,
150–210 220 – 325 220–330 240–350 10-18 (5-9) 8-12 (4-6) 12-25 (6-12) 10-20 (5-10)
(3.2mm) or 10
5/32" 12-25 (6-12)
8 or 10 200–275 300–425 375–475 400–500 15-25 (7-12) 10-15 (5-7) 15-30 (7-14)
(4.0mm)
3/16" 15-30 (7-14)
8 or 10 250–350 400 –525 475–800 475–800 20-35 (10-17) 12-25 (6-12) 25-40 (12-19)
(4.8mm)
1/4" 25-45 (12-21)
(6.4mm) 10 325–700 500–700 750–1000 700–1000 25-50 (12-24) 20-35 (10-17) 30-55 (14-26)
For pure helium shielding gas, double flow rates shown. For argon-helium mixes with below 30% helium content, use figures shown. Always adjust gas flows to
accommodate best shielding results.

TUNGSTEN ELECTRODE TIP SHAPES AND CURRENT RANGES

ELECTRODE DIAMETER DIAMETER AT TIP
CURRENT PULSED CURRENT
Millimeters Inches Millimeters Inches INCLUDED ANGLE RANGE RANGE
1.0mm .040" .125mm .005" 12° 2–15 amps 2–25 amps
1.0mm .040" .250mm .010" 20° 5–30 amps 5–60 amps
1.6mm 1/16" .500mm .020" 25° 8–50 amps 8–100 amps
1.6mm 1/16" .800mm .030" 30° 10–70 amps 10–140 amps
2.4mm 3/32" .800mm .030" 35° 12–90 amps 12–180 amps
2.4mm 3/32" 1.100mm .045" 45° 15–150 amps 15–250 amps
3.2mm 1/8" 1.100mm .045" 60° 20–200 amps 20–300 amps
3.2mm 1/8" 1.500mm .060" 90° 25–250 amps 25–350 amps

COrrect torch and rod positioning

Vertical
15°
Take special note that the filler rod is in the
shielding gas during the welding process.

Filler Rod
85°
Shield Gas
15°– 30°

Travel Direction

Follow us: Back To Table of Contents

6 P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com

 TUNGSTEN tip prepAration TUNGSTEN extension
STANDARD PARTS
Flat: 1/4 TO 1/2 X DIA

General Purpose 3 X DIA

DC
Taper Length: 2-3 X DIA

Typical Tip Geometry GAS LENS PARTS

for Inverter

AC Typical Tip Geometry General Purpose 3 X DIA

for Transformer
Maximum Ball Size: 1 X DIA

Ball tip by arcing on non-ferrous metal at low current DCRP (EP) then slowly
increase current to form the desired ball diameter. Return setting to AC. MAX: 6 X DIA. (In draft-free areas)

TUNGSTEN GRINDING

Use a medium (60 grit or finer)

aluminum oxide wheel.

• Grind longitudinally (never radially)

• Truncate (blunt) end The included angle determines weld bead shape
• Diameter of flat spot determines amperage capacity and size. Generally, as the included angle increases,
penetration increases and bead width decreases.
*Refer to page 5

COLOR CODE FOR TUNGSTEN ELECTRODES

Designation Chemical Composition Impurities ≤0.1%
ISO 6848 AWS A5.12 Oxide Additive Tungsten Tip Color
WT20 EWTh-2 ThO2: 1.70–2.20% 2% THORIATED Red
WP EWP ~~~~~~ PURE Green
WL15 EWLa-1.5 LaO2: 1.30 –1.70% 1.5% LANTHANATED Gold
WC20 EWCe-2 CeO2: 1.80– 2.20% 2% CERIATED Gray
WL20 EWLa-2 La2O3: 1.80–2.20% 2% LANTHANATED Blue
WZ8 EWZr-8 ZrO2: 0.70–0.90% 0.8% ZIRCONIATED White
1.5% LANTHANATED
LaYZr™ EWG La2O3: 1.3–1.7%; Y2O3: 0.06–0.10%; 0.8% YTTRIATED Chartreuse
ZrO2: 0.6–1.0% 0.8% ZIRCONIATED

Follow us: Back To Table of Contents

P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com 7
 TUNGSTEN Electrode Characteristics
Tungsten Color Code Characteristics
Provides good arc stability for AC welding. Reasonably good resistance to contamination. Lowest
Pure current carrying capacity. Least expensive. Maintains a balled end. Used on transformer based
Green machines only.

Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life.
2% Ceriated Possible replacement for thoriated.
Gray

Easier arc starting. Higher current capacity. Greater arc stability. High resistance to weld pool
2% Thoriated contamination. Difficult to maintain balled end on AC.
Red

1.5% Lanthanated
Gold Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life, high
current capacity. 1.5% possible replacement for thoriated. 2% possible replacement for Pure.
2% Lanthanated
Blue
Excellent for AC welding due to favorable retention of balled end, high resistance to
.8% Zirconiated contamination, and good arc starting. Preferred when tungsten contamination of weld is
White intolerable. Possible replacement for Pure.

Best for use on automated or robotic applications. Runs cooler than 2% Thoriated with longer life.
LaYZr™ Low to medium amperage range.
Chartreuse*
*Substitute for Purple (Same oxide blend).

TUNGSTEN Electrode CURRENT RANGES

Typical Current Range
Direct Current, DC Alternating Current, AC
DCEN 70% Penetration (50/50) Balanced Wave, AC
Ceriated Zirconiated Ceriated Zirconiated Ceriated

Thoriated Thoriated Pure Thoriated

Tungsten Gas Cup
Diameter in (Inside
inches (mm) Diameter)
Lanthanated Lanthanated LaYZr™ Lanthanated

LaYZr™ LaYZr™ LaYZr™

.040" (1.0) #5 (3/8") 15-80 amps 20-60 amps 15-80 amps 10-30 amps 20-60 amps
1/16" (1.6) #5 (3/8") 70-150 amps 50-100 amps 70-150 amps 30-80 amps 60-120 amps
3/32" (2.3) #8 (1/2") 150-250 amps 100-160 amps 140-235 amps 60-130 amps 100 -180 amps
1/8" (3.2) #8 (1/2") 250-400 amps 150-200 amps 225-325 amps 100-180 amps 160-250 amps
All values are based on the use of Argon as a shielding gas. Other current values may be employed depending on the shielding gas, type of
equipment, and application. DCEN = Direct Current Electrode Negative (Straight Polarity)

Follow us: Back To Table of Contents

8 P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com

 Weld Penetration profile

Gas
Type
30° Angle 60° Angle 90° Angle
.005" FLAT .010" FLAT .020" FLAT

100Ar
100% Argon

75Ar-25He
75% Argon
25% Helium

50Ar-50He
50% Argon
50% Helium

25Ar-75He
25% Argon
75% Helium

100He
100% Helium

95Ar-5H
95% Argon
5% Hydrogen

Follow us: Back To Table of Contents

P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com 9
 ALUMINUM (ACHF)
SHIELD GAS FLOW
WELDING ALUMINUM
METAL JOINT TUNGSTEN FILLER ROD CUP WELDING TRAVEL The use of TIG welding for aluminum has many
GAUGE TYPE SIZE SIZE SIZE CFH AMPERES SPEED
TYPE
(L/MN)
PSI advantages for both manual and automatic
processes. Filler metal can be either wire or rod
12
BUTT 60-80
(307.2mm)
and should be compatible with the base alloy.
1/16 1/16
(1.6mm) (1.6mm)
1/16 (1.6mm) 4, 5, 6 ARGON 15 (7) 20 Filler metal must be dry, free of oxides, grease,
10
FILLET 70-90
(256mm) or other foreign matter. If filler metal becomes
damp, heat for 2 hours at 250°F (121°C) before
3/32 (2.4mm) 12
BUTT
1/8 (3.2mm)
125-145
(307.2mm) using. Although ACHF is recommended, DCRP has
1/8 3/32
(3.2mm) (2.4mm)
6, 7 ARGON 17 (8) 20 been successful up to 3/32” (2.4mm), DCSP with
3/32 (2.4mm) 10
FILLET
1/16 (1.6mm)
140-160
(256mm) helium shield gas is successful in mechanized
applications.
11
BUTT 195-220
3/16 ARGON/ (258.6mm)
1/8 (3.2mm) 1/8 (3.2mm) 7, 8 21 (10) 20
(4.8mm) HELIUM 9
FILLET 210-240
(230.4mm)
10
BUTT 260-300
1/4 3/16 ARGON/ (256mm)
1/8 (3.2mm) 8, 10 25 (12) 20
(6.4mm) (4.8mm) HELIUM 8
FILLET 280-320
(204.8mm)

TITANIUM (DCSP) WELDING TITANIUM

SHIELD GAS FLOW Small amounts of impurities, particularly oxygen
METAL JOINT TUNGSTEN FILLER ROD CUP WELDING TRAVEL
GAUGE TYPE SIZE SIZE SIZE CFH AMPERES SPEED
and nitrogen, cause embrittlement of molten or hot
TYPE PSI
(L/MN) titanium when above 500°F (260°C). The molten
BUTT 90-110 10 (256mm) weld metal in the heat-affected zones must be
1/16 1/16 shielded by a protective blanket of inert gas. Tita-
NONE 4, 5, 6 ARGON 15 (7) 20 8
(1.6mm) FILLET (1.6mm) 110-150
(204.8mm) nium requires a strong, positive pressure of argon
or helium as a backup on the root side of the weld,
9
BUTT 190-220 as well as long, trailing, protective tail of argon gas
1/8 3/32 1/16 (230.4mm)
5, 6, 7 ARGON 15 (7) 20 to protect the metal while cooling. Purge chambers
(3.2mm) (2.4mm) (1.6mm) 7
FILLET 210-250 and trailing shields are available from CK Worldwide
(179.2mm)
8
to assist in providing quality results.
BUTT 220-250
3/16 3/32 (204.8mm)
1/8 (3.2mm) 6, 7, 8 ARGON 20 (10) 20
(4.8mm) (2.4mm) 7
FILLET 240-280
(179.2mm)
8
BUTT 275-310
1/4 (204.8mm)
1/8 (3.2mm) 1/8 (3.2mm) 8, 10 ARGON 30 (15) 20
(6.4mm) 7
FILLET 290-340
(179.2mm)

MAGNESIUM (ACHF) WELDING MAGNESIUM

SHIELD GAS FLOW Magnesium was one of the first metals to be
METAL JOINT TUNGSTEN FILLER ROD CUP WELDING TRAVEL
GAUGE TYPE SIZE SIZE SIZE CFH AMPERES SPEED welded commercially by TIG. Magnesium alloys
TYPE PSI
(L/MN) are in three groups, they are: (1) aluminum-
1/16 BUTT 1/16 3/32 (2.4mm) 60 20
zinc-magnesium, (2) aluminum-magnesium, and
5, 6 ARGON 13 (5) 15 (3) maganese-magnesium. Since magnesium
(1.6mm) FILLET (1.6mm) 1/8 (3.2mm) 60 (512mm)
absorbs a number of harmful ingredients and
1/8 BUTT 3/32 1/8 (3.2mm) 115 17
7, 8 ARGON 19 (9) 15 oxiodize rapidly when subjected to welding
(3.2mm) FILLET (2.4mm) 5/32 (4.0mm) 115 (435.2mm)
heat, TIG welding in an inert gas atmosphere
BUTT 100-130
22 is distinctly advantageous. The welding of
1/4 3/16 (563.2mm) magnesium is similar, in many respects, to the
5/32 (4.0mm) 8 ARGON 25 (12) 15
(6.4mm) (4.8mm) 20 welding of aluminum. Magnesium requires a
FILLET 110-135
(512mm) positive pressure of argon as a backup on the root
1/2 BUTT 10 side of the weld.
1/4 (6.4mm) 3/16 (4.8mm) 10 ARGON 35 (17) 15 260
(12.8mm) FILLET (256mm)

Follow us: Back To Table of Contents

10 P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com

 DEOXIDIZED COPPER (DCSP)
SHIELD GAS FLOW
WELDING DEOXIDIZED COPPER
METAL JOINT TUNGSTEN FILLER ROD CUP WELDING TRAVEL Where extensive welding is to be done, the use of
GAUGE TYPE SIZE SIZE SIZE CFH AMPERES SPEED
TYPE
(L/MN)
PSI deoxidized (oxygen-free) copper is preferable over
electrolytic tough pitch copper. Although TIG welding
12
BUTT 110-140
(307.2mm)
has been used occasionally to weld zinc-bearing
1/16 1/16
(1.6mm) (1.6mm)
1/16 (1.6mm) 4, 5, 6 ARGON 18 (9) 15 copper alloys, such as brass and commercial
10
FILLET 130-150
(256mm) bronzes, it is not recommended because the shield-
ing gas does not suppress the vaporization of zinc.
11
BUTT 175-225
(258.6mm) For the same reason zinc bearing filler rods should
1/8 3/32
(3.2mm) (2.4mm)
3/32 (2.4mm) 4, 5, 6 ARGON 18 (9) 15 not be used. There is some preference of helium for
9
FILLET 200-250
(230.4mm) the inert
atmosphere in welding thickness above 1/8”
10
BUTT 190-225
(256mm) (3.2mm) because of the improved weld metal
3/16 36
(4.8mm)
1/8 (3.2mm) 1/8 (3.2mm) 8, 10 HELIUM
(17.5)
15 fluidity. Preheating recommendations should be
8
FILLET 205-250
(204.8mm) followed.
9
BUTT (2) 225-260
1/4 3/16 36 (230.4mm)
1/8 (3.2mm) 8, 10 HELIUM 15
(6.4mm) (4.8mm) (17.5) 7
FILLET 250-280
(179.2mm)

STAINLESS STEEL (DCSP) WELDING STAINLESS STEEL

SHIELD GAS FLOW In TIG welding of stainless steel, welding rods
METAL JOINT TUNGSTEN FILLER CUP WELDING TRAVEL
GAUGE TYPE SIZE ROD SIZE SIZE TYPE
CFH
PSI AMPERES SPEED having the AWS-ASTM prefixes of E or ER can be
(L/MN)
used as filler rods. However, only bare uncoated
BUTT 80-100
12 rods should be used. Light gauge metals less then
1/16 1/16 (307.2mm)
(1.6mm)
1/16 (1.6mm)
(1.6mm)
4, 5, 6 ARGON 11 (5.5) 20 1/16” (1.6mm) thick should always be welded
FILLET 90-100 10 (256mm) with DCSP using argon gas. Follow the normal
12 pecautions for welding stainless such as: Clean
BUTT 120-140
1/8
1/16 (1.6mm)
3/32
4, 5, 6 ARGON 11 (5.5) 20
(307.2mm) surfaces; dry electrodes; use only stainless steel
(3.2mm) (2.4mm)
FILLET 130-150 10 (256mm) tools and brushes, keep stainless from coming in
contact with other metals.
12
BUTT 3/32 (2.4mm) 200-250
3/16 1/8 (307.2mm)
5, 6, 7 ARGON 13 (6) 20
(4.8mm) 3/32 (2.4mm) (3.2mm)
FILLET 225-275 10 (256mm)
1/8 (3.2mm)
BUTT 275-350 10 (256mm)
1/4 3/16
1/8 (3.2mm) 8, 10 ARGON 13 (6) 20 8
(6.4mm) FILLET (4.8mm) 300-375
(204.8mm)

LOW ALLOY STEEL (DCSP) WELDING LOW ALLOY STEEL

SHIELD GAS FLOW Mild and low carbon steels with less then 0.30%
METAL JOINT TUNGSTEN FILLER CUP WELDING TRAVEL
GAUGE TYPE SIZE ROD SIZE SIZE TYPE
CFH
PSI AMPERES SPEED carbon and less than 1” (2.5cm) thick, generally do
(L/MN) not require preheat. An exception to this allowance
1/16 BUTT 1/16 95-135 15 (384mm) is welding on highly restrained joints. These joints
1/16 (1.6mm) 4, 5, 6 ARGON 15 (7) 20
(1.6mm) FILLET (1.6mm) 95-135 15 (384mm) should be preheated 50 to 100°F (10 to 38°C) to
minimize shrinkage cracks in the base metal. Low
BUTT 145-205 11 (258.6mm)
1/8 1/16 (1.6mm) 3/32
4, 5, 6 ARGON 15 (7) 20
alloy steels such as the chromium-molybdenum
(3.2mm) 3/32 (2.4mm) (2.4mm) steels will have hard heat affected zones after
FILLET 145-205 11 (258.6mm)
welding, if the preheat temperature is too low. This
3/16 BUTT 1/8 210-260 10 (256mm)
3/32 (2.4mm) 7, 8 ARGON 16 (6.5) 20 is caused by rapid cooling of the base material and
(4.8mm) FILLET (3.2mm) 210-260 10 (256mm) the formation of martensitic grain structures. A 200
1/4 BUTT 5/32 240-300 10 (256mm) to 400°F (93 to 204°C) preheat temperature will
1/8 (3.2mm) 8, 10 ARGON 18 (8.5) 20
(6.4mm) FILLET (2) (4.0mm) 240-300 10 (256mm) slow the cooling rate and prevent the martensitic
structure.

Follow us: Back To Table of Contents

P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com 11
 TROUBLESHOOTING GUIDE
PROBLEM CAUSE SOLUTION
Inadequate gas flow Increase gas flow
Improper size electrode for current required Use larger electrode
Excessive Operating of reverse polarity Use larger electrode or change polarity
Electrode Electrode contamination Remove contaminated portion, then prepare again
Consumption Excessive heating inside torch Replace collect, try wedge collet or reverse collet
Electrode oxidizing during cooling Increase gas post flow time to 1 sec. per 10 amps
Shield gas incorrect Change to proper gas (no oxygen or Co2)
Incorrect voltage (arc too long) Maintain short arc length
Amperage too low for electrode size Use smaller electrode or increase amperage
Electrode contaminated Remove contaminated portion, then prepare again
Joint too narrow Open joint groove
Erratic Arc Contaminated shield gas, dark stains on the Most common cause is moisture or aspirated air in gas stream. Use welding
electrode or weld bead indicate contamination grade gas only. Find the source of contamination and eliminate it promptly.
Base metal is oxidized, dirty or oily Use appropriate chemical cleaners, wire brush or abrasives prior to welding.
Poor scratch starting technique Many codes do not allow scratch starts. Use copper strike plate.
Use high frequency arc starter.
Excessive amperage for tungsten size used. Reduce amperage or use larger electrode
Inclusion of Accidental contact of electrode with puddle Maintain proper arc length
Tungsten or Accidental contact of electrode to filler rod Maintain a distance between electrode and filler metal
Using excessive electrode extension Reduce electrode extension to recommended limits
Oxides in Weld
Inadequate shielding or excessive drafts Increase gas flow, shield arc from wind, or use gas lens
Wrong gas Do not use Ar-02 or Ar-Co2 GMA (MIG) gases for TIG welding
Heavy surface oxides not being removed Use ACHF, adjust balance control for maximum cleaning, or wire brush
and clean the weld joint prior to welding.
Entrapped impurities, hydrogen, air, nitrogen, Do not weld on wet material. Remove condensation from line
water vapor with adequate gas pre-flow time.
Defective gas hose or loose connection Check hoses and connections for leaks
Filler material is damp (particularly aluminum) Dry filler metal in over prior to welding
Porosity in Filler material is oily or dusty Replace filler metal
Weld Deposit Alloy impurities in the base metal such as sulphur, Change to a different alloy composition which is weldable. These impurities
phosphorus, lead and zinc can cause a tendency to crack when hot.
Excessive travel speed with rapid freezing of weld Lower the travel speed
trapping gases before they escape
Contaminated gas shield Replace the shielding gas
Hot cracking in heavy section or with metals Preheat, increase weld bead cross-section size, change weld bead contour.
which are hot shorts Use metal with fewer alloy impurities.
Crater cracks due to improperly breaking the arc Reverse direction and weld back into previous weld at edge. Use Aptrack or
Cracking in or terminating the weld at the joint edge foot control to manually down slope amperage.
Welds Post weld cold cracking, due to excessive joint Preheat prior to welding, use pure to non-contaminated gas. Increase the
restraint, rapid cooling, or hydrogen embrittlement bead size. Prevent craters or notches. Change the weld joint design.
Centerline cracks in single pass welds Increase bead size. Decrease root opening, use preheat, prevent craters.
Underbead cracking from brittle microstructure Eliminate sources of hydrogen, joint restraint, and use preheat.
Gas flow blockage or leak in hoses or torch Locate and eliminate blockage or leak.
Excessive travel speed exposes molten weld to Use slower travel speed or carefully increase the flow rate to a safe
Inadequate atmospheric contamination level below creating excessive turbulence. Use trailing shield cup.
Shielding Wind or drafts Set up screens around the weld area
Excessive electrode stickout Reduce electrode stickout. Use a larger size cup.
Excessive turbulence in gas stream Change to gas saver parts or gas lens parts.
Induced magnetic field from DC weld amperage Change to ACHF amperage. Rearrange the split ground connection.
Arc Blow Arc is unstable due to magnetic influences Reduce weld amperage and use arc length as short as possible.
Short WATER-COOLED leads life Verify coolant flow direction, return flow must be on the power cable lead.
Cup shattering or breaking in use Change cup size or type, change tungsten position, refer to CK Worldwide
technical specifications available at www.CKWorldwide.com
Short Short collet life Ordinary style is split and twists or jams, change to wedge style.
Short torch head life Do not operate beyond rated capacity, use WATER-COOLED model, do not
Parts Life bend
rigid torches
Gas hoses ballooning, bursting or blowing off Incorrect flowmeter, TIG flowmeters operate at 35 psi with low flows.

FORM 116
©2015 CK Worldwide, Inc. All rights reserved. 1.5K 4/2015

Follow us: Back To Table of Contents

12 P: (253) 854.5820 | F: (253) 939.1746 | Toll Free: (800) 426.0877 | www.Ckworldwide.com