1: Tungsten burning away quickly
Possible Reason
Suggested Remedy
Incorrect Gas or No Gas
Use pure Argon. Check cylinder has gas, connected, turned on and torch valve is open
Inadequate gas flow
Check the gas is connected, check hoses, gas valve and torch are not restricted.
Back cap not fitted correctly
Make sure the torch back cap is fitted so that the O-ring is inside the torch body
Torch connected to DC +
Connect the torch to the DC- output terminal
Incorrect tungsten being used
Check and change the tungsten type if necessary
Tungsten being oxidised after weld is
finished
Keep shielding gas flowing 10–15 seconds after arc stoppage. 1 second for each 10 amps of weld
current.
2: Contaminated tungsten
Possible Reason
Suggested Remedy
Touching tungsten into the weld pool
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work
piece 2 - 5mm
Touching the filler wire to the tungsten
Keep the filler wire from touching the tungsten during welding, feed the filler wire into the leading
edge of the weld pool in front of the tungsten
3: Porosity - poor weld appearance and colour
Possible Reason
Suggested Remedy
Wrong gas / poor gas flow /gas leaks
Use pure argon. Gas is connected, check hoses, gas valve and torch are not restricted. Set the gas
flow between 6-12 l/min. Check hoses and fittings for holes, leaks etc.,
Contaminated base metal
Remove moisture and materials like paint, grease, oil, and dirt from base metal
Contaminated filler wire
Remove all grease, oil, or moisture from filler metal.
Incorrect filler wire
Check the filler wire and change if necessary
4: Yellowish residue / smoke on the alumina nozzle & discoloured tungsten
Possible Reason
Suggested Remedy
Incorrect Gas
Use pure Argon gas
Inadequate gas flow
Set the gas flow between 10 - 15 l/min flow rate
Alumina gas nozzle too small
Increase the size of the alumina gas nozzle
5: Unstable Arc during DC welding
Possible Reason
Suggested Remedy
Torch connected to DC +
Connect the torch to the DC- output terminal
Contaminated base metal
Remove materials like paint, grease, oil, and dirt, including mill scale from base metal.
Tungsten is contaminated
Remove 10mm of contaminated tungsten and re grind the tungsten
Arc length too long
Lower torch so that the tungsten is off of the work piece 2 - 5mm
6: Arc wanders during DC welding
Possible Reason
Suggested Remedy
Poor gas flow
Check and set the gas flow between 10 - 15 l/min flow rate
Incorrect arc length
Lower torch so that the tungsten is off of the work piece 2 - 5mm
Tungsten incorrect or in poor condition
Check that correct type of tungsten is being used. Remove 10mm from the weld end of the tungsten
and re sharpen the tungsten
Poorly prepared tungsten
Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and
wheel.
Contaminated base metal or filler wire
Remove contaminating materials like paint, grease, oil, and dirt, including mill scale from base metal.
Remove all grease, oil, or moisture from filler metal.
7: Arc difficult to start or will not start DC welding
Possible Reason
Suggested Remedy
Incorrect machine set up
Check machine set up is correct
No gas, incorrect gas flow
Check the gas is connected and cylinder valve open, check hoses, gas valve and torch are not
restricted. Set the gas flow between 10 - 15 l/min flow rate
Incorrect tungsten size or type
Check and change the size and or the tungsten if required
Loose connection
Check all connectors and tighten
Earth clamp not connected to work
Connect the earth clamp directly to the work piece wherever possible
The following chart addresses some of the common problems of DC TIG welding. In all cases of equipment malfunction, the manufacturer’s
recommendations should be strictly adhered to and followed.
42
| VIPER MIG 185 Manual
TIG WELDING TROUBLE SHOOTING
