TECHNICAL

SPECIFICATIONS
FOR TIG WELDING

THE STANDARD
IN TIG WELDING
Form 116April 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

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TABLE OF CONTENTS
TIG TORCH CONNECTION DIAGRAMS
GAS-COOLED TORCHES
WATER-COOLED TORCHES

3
3

CHARACTERISTICS OF CURRENT TYPES FOR TIG WELDING

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

4
4
4
5
5

SHIELD GAS SELECTION AND USE

FREE ONLINE TIG

WELDING TRAINING

CK Worldwide offers an introduction to

TIG torches, how they are made, and
how to select the right torch for the job.
Visit www.WELDTRAIN.com

GUIDE FOR SHIELD GAS FLOWS, CURRENT

SETTINGS, CUP SELECTION
TUNGSTEN ELECTRODE TIP SHAPES
AND CURRENT RANGES
CORRECT TORCH AND ROD POSITIONING

6
6
6

TUNGSTEN SELECTION AND PREPARATION

TUNGSTEN TIP PREPERATION
TUNGSTEN EXTENSION
TUNGSTEN GRINDING
COLOR CODE FOR TUNGSTEN ELECTRODES

WeldTRAIN

7
7
7
7

Online Training for the Welding, Gases, and Safety Industry.

Free training - on your own time!

TUNGSTEN CHARACTERISTICS AND PENETRATION PROFILES

TUNGSTEN ELECTRODE CHARACTERISTICS
TUNGSTEN ELECTRODE CURRENT RANGES
WELD PENETRATION PROFILES

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8
8
9

TYPICAL MANUAL TIG WELDING PARAMETERS

ALUMINUM 10
TITANIUM 10
MAGNESIUM 10
DEOXIDIZED COPPER
11
STAINLESS STEEL
11
LOW ALLOY STEEL
11

Product demonstrations,
welding tips and more.

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The information in this manual represents the best judgement of CK Worldwide, Inc. and is intended for
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
or implied, as to the viability of this information for any application or use. The individual user is solely
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.

EXCESSIVE ELECTRODE CONSUMPTION

ERRATIC ARC
INCLUSION OF TUNGSTEN OR OXIDES IN WELD
POROSITY IN WELD DEPOSIT
CRACKING IN WELDS
INADEQUATE SHIELDING
ARC BLOW
SHORT PARTS LIFE

12
12
12
12
12
12
12
12

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connection diagrams
2 Piece gas cooled

1 piece gas cooled

Valve
Valve
Lug
Dinse
Gas In
Gas In

Water cooled gas-thru

1 piece 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

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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

produces deep penetration by
concentrating heat in the joint area.
No cleaning action occurs with this
polarity.

Direct Current Reverse Polarity

produces the best cleaning action as
the argon ions flowing towards the
work strike with sufficient force to
break up oxides on the surface.

Alternating Current High Frequency

combines the weld penetration on the
negative half cycle with the cleaning
action of the positive half cycle. High
frequency re-establishes the arc which
breaks each half cycle on transformer
based machines.

CURRENT TYPE

DCSP

CURRENT TYPE

DCRP

CURRENT TYPE

ACHF

ELECTRODE
POLARITY

Electrode negative

ELECTRODE
POLARITY

Electrode positive

ELECTRODE
POLARITY

Alternating

OXIDE CLEANING
ACTION

No

OXIDE CLEANING
ACTION

Yes

OXIDE CLEANING
ACTION

Yes (once every

half cycle)

HEAT BALANCE
IN THE ARC

70% of work end

30% at electrode end

HEAT BALANCE
IN THE ARC

30% of work end

70% at electrode end

HEAT BALANCE
IN THE ARC

50% of work end

50% at electrode end

PENETRATION
PROFILE

Deep narrow

PENETRATION
PROFILE

Shallow wide

PENETRATION
PROFILE

Medium

ELECTRODE
CAPACITY

Excellent

ELECTRODE
CAPACITY

Poor

ELECTRODE
CAPACITY

Good

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

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 selecting the correct torch nozzle material

CUP CHART

ALUMINA

CERAMIC

SUPER CUP

PYREX

High impact resistance

Low thermal shock
(Aluminum Oxide)

High thermal shock

Low impact resistance
(Lava)

High thermal shock

High impact resistance
(Silicon Nitride)

High visibility
Low thermal shock
Low impact resistance
(Pyrex)

Exit diameter measured in

1/16 (1.6mm) increments

Designed to fit
GTAW torches

gas lens benefits

40% Argon savings
Columnar flow gas pattern
Standard
Collet
& Collet
Body

Gas Saver
Collet
& Collet
Body

Longer electrode stick-out

Lower gas flow rates
Better visibility

Turbulent gas
flow pattern

Columnar gas
flow pattern

Longer parts life

Cleaner welds

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 GUIDE FOR SHIELD GAS FLOWS, CURRENT SETTINGS & CUP SELECTION
WELDING CURRENT (AMPS) TUNGSTEN TYPE

ARGON FLOW FERROUS METALS

ARGON FLOW ALUMINUM

Electrode
Diameter

Cup Size

AC
Pure

AC
Thoriated

DCSP
Pure

DCSP
Thoriated

Standard Body
CFH (L/MN)

Gas Lens Body

CFH (L/MN)

Standard Body Gas Lens Body

CFH (L/MN)
CFH (L/MN)

.020"
(0.5mm)

3, 4, or 5

515

5 20

515

520

5-8 (3-4)

5-8 (3-4)

5-8 (3-4)

5-8 (3-4)

.040"
(1.0mm)

4 or 5

1060

15 80

1570

2080

5-10 (3-5)

5-8 (3-4)

5-12 (3-6)

5-10 (3-5)

1/16"
(1.6mm)

4, 5, or 6

50100

70 150

70130

80150

7-12 (4-6)

5-10 (3-5)

8-15 (4-7)

7-12 (4-6)

3/32"
(2.4mm)

6, 7, or 8

100160

140235

150220

150250

10-15 (5-7)

8-10 (4-5)

10-20 (5-10)

10-15 (5-7)

1/8"
(3.2mm)

7, 8,
or 10

150210 220 325

220330

240350

10-18 (5-9)

8-12 (4-6)

12-25 (6-12)

10-20 (5-10)

5/32"
(4.0mm)

8 or 10

200275

300425

375475

400500

15-25 (7-12)

10-15 (5-7)

15-30 (7-14)

12-25 (6-12)

3/16"
(4.8mm)

8 or 10

250350 400 525

475800

475800

20-35 (10-17)

12-25 (6-12)

25-40 (12-19)

15-30 (7-14)

1/4"
(6.4mm)

10

325700 500700

7501000

7001000

25-50 (12-24)

20-35 (10-17)

30-55 (14-26)

25-45 (12-21)

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

Millimeters

Inches

Millimeters

Inches

INCLUDED ANGLE

CURRENT
RANGE

PULSED CURRENT
RANGE

1.0mm

.040"

.125mm

.005"

12

215 amps

225 amps

1.0mm

.040"

.250mm

.010"

20

530 amps

560 amps

1.6mm

1/16"

.500mm

.020"

25

850 amps

8100 amps

1.6mm

1/16"

.800mm

.030"

30

1070 amps

10140 amps

2.4mm

3/32"

.800mm

.030"

35

1290 amps

12180 amps

2.4mm

3/32"

1.100mm

.045"

45

15150 amps

15250 amps

3.2mm

1/8"

1.100mm

.045"

60

20200 amps

20300 amps

3.2mm

1/8"

1.500mm

.060"

90

25250 amps

25350 amps

COrrect torch and rod positioning

15

Vertical

Take special note that the filler rod is in the

shielding gas during the welding process.

85

Filler Rod
Shield Gas
15 30

Travel Direction

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 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

GAS LENS PARTS

Typical Tip Geometry

for Inverter

AC

General Purpose 3 X DIA

Typical Tip Geometry

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
Diameter of flat spot determines amperage capacity

The included angle determines weld bead shape

and size. Generally, as the included angle increases,
penetration increases and bead width decreases.
*Refer to page 5

COLOR CODE FOR TUNGSTEN ELECTRODES

Chemical Composition Impurities 0.1%

Designation
ISO 6848

AWS A5.12

Oxide Additive

Tungsten

WT20

EWTh-2

ThO2: 1.702.20%

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: 1.802.20%

2% LANTHANATED

Blue

WZ8

EWZr-8

ZrO2: 0.700.90%

0.8% ZIRCONIATED

White

LaYZr

EWG

La2O3: 1.31.7%; Y2O3: 0.060.10%;

ZrO2: 0.61.0%

1.5% LANTHANATED
0.8% YTTRIATED
0.8% ZIRCONIATED

Chartreuse

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 TUNGSTEN Electrode Characteristics

Tungsten
Pure
2% Ceriated

Color Code

Characteristics

Green

Provides good arc stability for AC welding. Reasonably good resistance to contamination. Lowest
current carrying capacity. Least expensive. Maintains a balled end. Used on transformer based
machines only.

Gray

2% Thoriated

Red

1.5% Lanthanated

Gold

2% Lanthanated

Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life.
Possible replacement for thoriated.
Easier arc starting. Higher current capacity. Greater arc stability. High resistance to weld pool
contamination. Difficult to maintain balled end on AC.

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.

Blue

.8% Zirconiated

White

LaYZr

Chartreuse*

Excellent for AC welding due to favorable retention of balled end, high resistance to
contamination, and good arc starting. Preferred when tungsten contamination of weld is
intolerable. Possible replacement for Pure.
Best for use on automated or robotic applications. Runs cooler than 2% Thoriated with longer life.
Low to medium amperage range.

*Substitute for Purple (Same oxide blend).

TUNGSTEN Electrode CURRENT RANGES

Typical Current Range
Direct Current, DC

Alternating Current, AC

DCEN

Ceriated

Tungsten
Diameter in
inches (mm)

Gas Cup
(Inside
Diameter)

70% Penetration

Zirconiated

(50/50) Balanced Wave, AC

Ceriated

Zirconiated

Ceriated

Thoriated

Thoriated

Pure

Thoriated

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)

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 Weld Penetration profile

Gas
Type
30 Angle
.005" FLAT

60 Angle
.010" FLAT

90 Angle
.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

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 ALUMINUM (ACHF)
METAL
GAUGE

1/16
(1.6mm)

1/8
(3.2mm)

3/16
(4.8mm)

1/4
(6.4mm)

JOINT
TYPE
BUTT
FILLET
BUTT
FILLET

TUNGSTEN
SIZE

1/16
(1.6mm)

3/32
(2.4mm)

FILLER ROD
SIZE

1/16 (1.6mm)

3/32 (2.4mm)
1/8 (3.2mm)
3/32 (2.4mm)
1/16 (1.6mm)

CUP
SIZE

4, 5, 6

6, 7

BUTT
1/8 (3.2mm)

1/8 (3.2mm)

7, 8

FILLET
BUTT
FILLET

3/16
(4.8mm)

1/8 (3.2mm)

8, 10

WELDING ALUMINUM

SHIELD GAS FLOW

TYPE

ARGON

ARGON

ARGON/
HELIUM

ARGON/
HELIUM

CFH
(L/MN)

PSI

15 (7)

WELDING
AMPERES

TRAVEL
SPEED

60-80

12
(307.2mm)

70-90

10
(256mm)

125-145

12
(307.2mm)

140-160

10
(256mm)

195-220

11
(258.6mm)

210-240

9
(230.4mm)

260-300

10
(256mm)

280-320

8
(204.8mm)

20

17 (8)

20

21 (10)

20

25 (12)

20

TITANIUM (DCSP)
METAL
GAUGE

1/16
(1.6mm)

1/8
(3.2mm)

3/16
(4.8mm)

1/4
(6.4mm)

JOINT
TYPE
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET

WELDING TITANIUM
SHIELD GAS FLOW

TUNGSTEN
SIZE

FILLER ROD
SIZE

CUP
SIZE

TYPE

CFH
(L/MN)

PSI

1/16
(1.6mm)

NONE

4, 5, 6

ARGON

15 (7)

20

3/32
(2.4mm)

1/16
(1.6mm)

3/32
(2.4mm)

1/8 (3.2mm)

5, 6, 7

6, 7, 8

ARGON

ARGON

15 (7)

20 (10)

1/8 (3.2mm)

8, 10

ARGON

30 (15)

WELDING
AMPERES

TRAVEL
SPEED

90-110

10 (256mm)

110-150

8
(204.8mm)

190-220

9
(230.4mm)

210-250

7
(179.2mm)

220-250

8
(204.8mm)

240-280

7
(179.2mm)

275-310

8
(204.8mm)

290-340

7
(179.2mm)

20

20

BUTT
1/8 (3.2mm)

20

FILLET

MAGNESIUM (ACHF)
JOINT
TYPE

TUNGSTEN
SIZE

FILLER ROD
SIZE

CUP
SIZE

1/16
(1.6mm)

BUTT
FILLET

1/16
(1.6mm)

3/32 (2.4mm)
1/8 (3.2mm)

1/8
(3.2mm)

FILLET

3/32
(2.4mm)

1/8 (3.2mm)
5/32 (4.0mm)

1/4
(6.4mm)

1/2
(12.8mm)

BUTT
FILLET
BUTT
FILLET

3/16
(4.8mm)

5/32 (4.0mm)

1/4 (6.4mm)

3/16 (4.8mm)

SHIELD GAS FLOW

TYPE

CFH
(L/MN)

PSI

5, 6

ARGON

13 (5)

15

7, 8

ARGON

19 (9)

15

10

ARGON

ARGON

25 (12)

35 (17)

WELDING
AMPERES

TRAVEL
SPEED

60

20
(512mm)

60
115
115
100-130

22
(563.2mm)

110-135

20
(512mm)

260

10
(256mm)

15

15

17
(435.2mm)

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Small amounts of impurities, particularly oxygen

and nitrogen, cause embrittlement of molten or hot
titanium when above 500F (260C). The molten
weld metal in the heat-affected zones must be
shielded by a protective blanket of inert gas. Titanium requires a strong, positive pressure of argon
or helium as a backup on the root side of the weld,
as well as long, trailing, protective tail of argon gas
to protect the metal while cooling. Purge chambers
and trailing shields are available from CK Worldwide
to assist in providing quality results.

WELDING MAGNESIUM

METAL
GAUGE

BUTT

The use of TIG welding for aluminum has many

advantages for both manual and automatic
processes. Filler metal can be either wire or rod
and should be compatible with the base alloy.
Filler metal must be dry, free of oxides, grease,
or other foreign matter. If filler metal becomes
damp, heat for 2 hours at 250F (121C) before
using. Although ACHF is recommended, DCRP has
been successful up to 3/32 (2.4mm), DCSP with
helium shield gas is successful in mechanized
applications.

Magnesium was one of the first metals to be

welded commercially by TIG. Magnesium alloys
are in three groups, they are: (1) aluminumzinc-magnesium, (2) aluminum-magnesium, and
(3) maganese-magnesium. Since magnesium
absorbs a number of harmful ingredients and
oxiodize rapidly when subjected to welding
heat, TIG welding in an inert gas atmosphere
is distinctly advantageous. The welding of
magnesium is similar, in many respects, to the
welding of aluminum. Magnesium requires a
positive pressure of argon as a backup on the root
side of the weld.

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 DEOXIDIZED COPPER (DCSP)

METAL
GAUGE

1/16
(1.6mm)

1/8
(3.2mm)

3/16
(4.8mm)

1/4
(6.4mm)

JOINT
TYPE
BUTT
FILLET
BUTT
FILLET

TUNGSTEN
SIZE

1/16
(1.6mm)

3/32
(2.4mm)

FILLER ROD
SIZE

1/16 (1.6mm)

3/32 (2.4mm)

TYPE

4, 5, 6

ARGON

4, 5, 6

ARGON

BUTT
1/8 (3.2mm)

1/8 (3.2mm)

8, 10

HELIUM

FILLET
BUTT (2)
FILLET

3/16
(4.8mm)

1/8 (3.2mm)

WELDING DEOXIDIZED COPPER

SHIELD GAS FLOW

CUP
SIZE

8, 10

HELIUM

CFH
(L/MN)

PSI

18 (9)

WELDING
AMPERES

TRAVEL
SPEED

110-140

12
(307.2mm)

130-150

10
(256mm)

175-225

11
(258.6mm)

200-250

9
(230.4mm)

190-225

10
(256mm)

205-250

8
(204.8mm)

225-260

9
(230.4mm)

250-280

7
(179.2mm)

15

18 (9)

15

36
(17.5)

15

36
(17.5)

15

STAINLESS STEEL (DCSP)

METAL
GAUGE

JOINT
TYPE

1/16
(1.6mm)

BUTT

1/8
(3.2mm)

3/16
(4.8mm)

1/4
(6.4mm)

FILLER
ROD SIZE

CUP
SIZE

TYPE

CFH
(L/MN)

PSI

1/16 (1.6mm)

1/16
(1.6mm)

4, 5, 6

ARGON

11 (5.5)

20

BUTT
1/16 (1.6mm)
FILLET
BUTT

3/32 (2.4mm)

FILLET

3/32 (2.4mm)
1/8 (3.2mm)

BUTT
FILLET

WELDING STAINLESS STEEL

SHIELD GAS FLOW

TUNGSTEN
SIZE

FILLET

1/8 (3.2mm)

3/32
(2.4mm)

4, 5, 6

1/8
(3.2mm)

5, 6, 7

3/16
(4.8mm)

8, 10

ARGON

ARGON

ARGON

11 (5.5)

13 (6)

13 (6)

WELDING
AMPERES

TRAVEL
SPEED

80-100

12
(307.2mm)

90-100

10 (256mm)

120-140

12
(307.2mm)

130-150

10 (256mm)

200-250

12
(307.2mm)

225-275

10 (256mm)

275-350

10 (256mm)

300-375

8
(204.8mm)

20

20

20

LOW ALLOY STEEL (DCSP)

METAL
GAUGE

JOINT
TYPE

1/16
(1.6mm)

BUTT

1/8
(3.2mm)
3/16
(4.8mm)
1/4
(6.4mm)

FILLET
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET (2)

FILLER
ROD SIZE

CUP
SIZE

1/16 (1.6mm)

1/16
(1.6mm)

4, 5, 6

SHIELD GAS FLOW

TYPE

CFH
(L/MN)

PSI

ARGON

15 (7)

20

1/16 (1.6mm)
3/32 (2.4mm)

3/32
(2.4mm)

4, 5, 6

ARGON

15 (7)

20

3/32 (2.4mm)

1/8
(3.2mm)

7, 8

ARGON

16 (6.5)

20

5/32
(4.0mm)

In TIG welding of stainless steel, welding rods

having the AWS-ASTM prefixes of E or ER can be
used as filler rods. However, only bare uncoated
rods should be used. Light gauge metals less then
1/16 (1.6mm) thick should always be welded
with DCSP using argon gas. Follow the normal
pecautions for welding stainless such as: Clean
surfaces; dry electrodes; use only stainless steel
tools and brushes, keep stainless from coming in
contact with other metals.

WELDING LOW ALLOY STEEL

TUNGSTEN
SIZE

1/8 (3.2mm)

Where extensive welding is to be done, the use of

deoxidized (oxygen-free) copper is preferable over
electrolytic tough pitch copper. Although TIG welding
has been used occasionally to weld zinc-bearing
copper alloys, such as brass and commercial
bronzes, it is not recommended because the shielding gas does not suppress the vaporization of zinc.
For the same reason zinc bearing filler rods should
not be used. There is some preference of helium for
the inert
atmosphere in welding thickness above 1/8
(3.2mm) because of the improved weld metal
fluidity. Preheating recommendations should be
followed.

8, 10

ARGON

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18 (8.5)

20

WELDING
AMPERES

TRAVEL
SPEED

95-135

15 (384mm)

95-135

15 (384mm)

145-205

11 (258.6mm)

145-205

11 (258.6mm)

210-260

10 (256mm)

210-260

10 (256mm)

240-300

10 (256mm)

240-300

10 (256mm)

Mild and low carbon steels with less then 0.30%

carbon and less than 1 (2.5cm) thick, generally do
not require preheat. An exception to this allowance
is welding on highly restrained joints. These joints
should be preheated 50 to 100F (10 to 38C) to
minimize shrinkage cracks in the base metal. Low
alloy steels such as the chromium-molybdenum
steels will have hard heat affected zones after
welding, if the preheat temperature is too low. This
is caused by rapid cooling of the base material and
the formation of martensitic grain structures. A 200
to 400F (93 to 204C) preheat temperature will
slow the cooling rate and prevent the martensitic
structure.

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 TROUBLESHOOTING GUIDE
PROBLEM

Excessive
Electrode
Consumption

Erratic Arc

Inclusion of
Tungsten or
Oxides in Weld

Porosity in
Weld Deposit

Cracking in
Welds

Inadequate
Shielding
Arc Blow

Short
Parts Life

CAUSE

SOLUTION

Inadequate gas flow

Increase gas flow
Improper size electrode for current required
Use larger electrode
Operating of reverse polarity
Use larger electrode or change polarity
Electrode contamination
Remove contaminated portion, then prepare again
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
Contaminated shield gas, dark stains on the Most common cause is moisture or aspirated air in gas stream. Use welding
grade gas only. Find the source of contamination and eliminate it promptly.
electrode or weld bead indicate contamination
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
Accidental contact of electrode with puddle Maintain proper arc length
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
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
Filler material is oily or dusty
Replace filler metal
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
Preheat, increase weld bead cross-section size, change weld bead contour.
Hot cracking in heavy section or with metals
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
or terminating the weld at the joint edge
foot control to manually down slope amperage.
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
atmospheric contamination
level below creating excessive turbulence. Use trailing shield cup.
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 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 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
bend

rigid torches
Gas hoses ballooning, bursting or blowing off
Incorrect flowmeter, TIG flowmeters operate at 35 psi with low flows.

FORM 116

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