TIG

TIG TROUBLESHOOTING GUIDE

55 causes and solutions to 8 common challenges

A. Burning Through Tungsten Too Quick

Possible Cause Possible Solution

Make sure hose, gas valve and torch are not restricted/the tank is not empty.
Inadequate gas flow
Gas flow should be set between 15-20 cfh.

Operating on DCEP (electrode positive) Switch to DCEN (electrode negative).

Wrong tungsten size for usage General purpose size is 3/32” diameter at a max of 220A.

TIG gun running too hot Air-cooled torches get warm. If using a water-cooled torch, coolant flow may be restricted or coolant may be low.

Tungsten oxidation during cooling Keep shielding gas flowing 1 second for each 10 amps of weld current after arc stoppage.

Use of oxygen or CO2 gasses Use Argon Gas. Helium or Argon/Helium blend gasses can also be used but are not required.

Tungsten melting back into cup If using pure tungsten, change to ceriated or lanthanated.

B. Tungsten Contamination

Possible Cause Possible Solution

Tungsten melting into puddle Use less current or larger tungsten. Use ceriated (AC or DC) thoriated (DC) or lanthanated tungsten (AC or DC).

Touching tungsten to puddle Keep tungsted from contact weld puddle. Raise torch so tungsten is off work piece 1/8” to 1/4”.

C. High-Frequency–No Arc Power

Possible Cause Possible Solution

Incomplete weld circuit Check work connection. Check all cable connections.

Check for gas flow at end of torch. Check for empty cylinder or closed shut-off valve.
No shielding gas
Gas flow should be set between 15-20 CFH.

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 TIG

TIG TROUBLESHOOTING GUIDE

55 causes and solutions to 8 common challenges

D. Yellow Powder/Smoke on Cup–Tungsten Discoloration

Possible Cause Possible Solution

Blow out air and moisture from lines. Remove condensation from base metal before welding. Metals stored in cold
Condensation on base metal
temperatures will condensate when exposed to warm temperatures.

Loose fittings in torch or hoses Tighten fittings in torch and all hoses.

Inadequate gas flow Adjust flow rate as necessary.

Defective gas hose or loose connection Replace gas hose and check connections for leaks, cuts, or pin holes.

Contaminated or improper filler metal Check filler metal type. Remove grease, oil or moisture from filler metal.

Base metal is contaminated Remove paint, grease and dirt, including mill scale from base metal.

E. Porosity In Weld/Poor Bead Color

Possible Cause Possible Solution

Blow out air and moisture from lines. Remove condensation from base metal before welding. Metals stored in cold
Condensation on base metal
temperatures will condensate when exposed to warm temperatures.

Loose fittings in torch or hoses Tighten fittings on torch and all hoses.

Inadequate gas flow Adjust flow rate as necessary.

Defective gas hose or loose connection Replace gas hose and check connections for leaks, cuts, or pin holes.

Contaminated or improper filler metal Check filler metal type. Remove grease, oil or moisture from filler metal.

Base metal is contaminated Remove paint, grease and dirt, including mill scale from base metal.

www.AmericanTorchTip.com | 941-753-7557 or 800-342-8477 | Made in the U.S.A.

 TIG

TIG TROUBLESHOOTING GUIDE

55 causes and solutions to 8 common challenges

F. Unstable Arc
DC Welding

Possible Cause Possible Solution

Check polarity switch on welder. Select DCEN (electrode negative). For applicable power sources ensure the torch is
Weld circuit polarity is incorrect
connected to the electrode holder terminal.

Tungsten is contaminated Remove 1/2” of contaminated tungsten and repoint tungsten.

Arc too long. Shorten arc length Lower torch so that the tungsten is off of the work piece no more than 1/8” to 1/4”.

Base metal is contaminated Remove paint, grease, oil and dirt, including mill scale from base metal.

AC Welding

Possible Cause Possible Solution

Excessive rectification in base metal Increase travel speed. Increase balance control toward minimum cleaning (higher percentage). Add filler metal.

Improper shielding gas When welding on 3/8” to 1/2” thick aluminum, use argon/helium.

Incorrect arc length Use correct arc length. Adjust the torch so that the tungsten is off work piece 1/8”-1/4”.

Tungsten is contaminated Remove 1/2” of contaminated tungsten using a high-speed abrasive and repoint tungsten.

Base metal is contaminated Remove paint, grease, oil and dirt, including mill scale from base metal.

Frequency set too low Increase AC frequency to give proper arc stability and direction. 100-180 Hertz is acceptable.

Improperly prepared tungsten With inverter machines, use slightly truncated tungsten. Tungsten may round off after welding.

www.AmericanTorchTip.com | 941-753-7557 or 800-342-8477 | Made in the U.S.A.

 TIG

TIG TROUBLESHOOTING GUIDE

55 causes and solutions to 8 common challenges

G. Arc Wanders
DC Welding

Possible Cause Possible Solution

Improper arc length/poor tungsten
Lower torch so that the tungsten is off of the work piece no more that 1/8” to 1/4”, clean and sharpen tungsten.
condition

Improperly prepared tungsten Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and wheel.

Light gray appearance on tungsten Repoint and slightly truncate. If heavily contaminated, remove 1/2” of tungsten using a high-speed abrasive.

Improper gas flow Gas flow should be set between 15-20 CFH.

AC Welding

Possible Cause Possible Solution

Improper tungsten preparation With inverter machines, use pointed tungsten. Point will eventually round off after welding.

Contaminated tungsten Remove 1/2” of contaminated tungsten using a high-speed abrasive and repoint tungsten.

Contaminated base metal Remove paint, grease, oil and dirt, including mill scale from base metal.

Incorrect balance control setting Increase balance toward minimum cleaning. Normal balance control setting is 70-90.

Wrong tungsten size and type Select correct size and type. General purpose tungsten is 3/32” in diameter and ceriated or thoriated.

Improper shielding gas flow Gas flow should be set between 15-20 CFH.

Increase AC frequency on machines so equipped to stabilize and direct the arc. Higher AC frequencies result in a
Frequency set too low
narrower arc column and can help achieve deeper penetration.

Excessive rectification in base metal Increase travel speed. Increase balance setting toward minimum cleaning. Add filler metal.

www.AmericanTorchTip.com | 941-753-7557 or 800-342-8477 | Made in the U.S.A.

 TIG

TIG TROUBLESHOOTING GUIDE

55 causes and solutions to 8 common challenges

H. Arc Not Starting/Hard To Start

DC Welding

Possible Cause Possible Solution

No shielding gas Gas flow should be set between 15-20 CFH.

Incorrect power supply switch positions Place switches in correct positions, either HF impulse or start HF.

Wrong tungsten electrode Use ceriated or thoriated tungsten.

Loose connections Tighten all cable and torch connections.

Incomplete weld circuit Make sure work clamp is connected.

Improper tungsten size Use smallest tungsten possible. Most common size is 3/32” in diameter.

AC Welding

Possible Cause Possible Solution

Incomplete weld circuit Check work clamp and make sure it’s securely fastened to work.

Incorrect cable installation Check circuit breakers and fuses. Check and tighten all cable connections.

No shielding gas Gas flow should be set between 15-20 CFH, check for gas flow at end of torch and check cylinder and valve.

Loss of high frequency Check torch and cables for cracked insulation or bad connections. Check spark gaps and adjust in necessary.

Wrong tungsten size Use smallest tungsten possible. Most common size is 3/32” in diameter.

Wrong tungsten type Use ceriated, thoriated or lanthanated tungsten.

www.AmericanTorchTip.com | 941-753-7557 or 800-342-8477 | Made in the U.S.A.