Frequent TIG Welding Issues

Written By Luke Alderfer

🔥 TIG Troubleshooting Guide

📋 Problem: Grey Stainless Steel Welds

  • Bad gas coverage?
  • Material overheating?
  • CFH high enough?
🔧 Fix: Up your cup size (the bigger the better + use gas lens), slow travel speed + not enough filler = material overheating/gray welds. Up your travel speed and use enough filler to keep weld puddle cool. 20-25 CFH minimum, however the bigger the cup, the more CFH needed.

📋 Problem: Porosity

  • Is CFH high enough?
  • Check for leaks in lines or torch.
  • Is material clean (free of oil, paint, rust, mill scale etc.)?
  • Is environment too windy?
🔧 Fix: Adjust gas flow, check connections, clean material, make sure air flow around the weld is not blowing away your gas.

📋 Problem: Arc Not Starting or Difficulty Starting Arc

  • Is your machine connections correct?
  • Is machine set to TIG high-frequency start if using foot pedal?
  • Is machine set to TIG lift-arc if using torch to initiate arc?
  • Is ground on clean metal and your welding clean metal?
🔧 Fix: Make sure your connections are setup for electrode negative (ground in positive terminal and electrode in negative), double check machine settings, double check material is clean where working and grounded.

📋 Problem: Trouble Getting Puddle Started And Trouble Welding With Aluminum Welding

  • Is there good enough gas coverage? (very overlooked)
  • Is material thick where it needs pre-heat?
  • Is material clean and free of oil, paint, corrosion etc.?
  • Is environment too windy?
  • Is the balance set right? (most machines 70% is a good starting point)
🔧 Fix: Ensure proper gas flow (20 CFH minimum), make sure gas coverage is good (make sure it welds good on other material types), make sure balance is set right so cleaning action is taking place (there should be a white ashy looking ring around weld bead), if welding thicker material, pre-heating it will help a lot

📋 Problem: Undercut

  • Adding enough filler?
  • Too high amperage?
  • Improper torch angle?
🔧 Fix: Make sure to add enough filler to fill out joint properly, lower amps slightly (if needed), make sure you always have a 10-15 degree push angle (angled away from the direction of travel) and as far as up and down torch angle try angling the torch to point the tungsten more towards the side of the joint that is undercutting
Luke Alderfer
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