Tig (Gtaw) Welding Problems - ESAB CIGWELD XF190 Operating Manual

TIG WELDING SETUP CHART
BASE METAL DC CURRENT
THICKNESS FOR MILD STEEL
0.040" 35-45
1.0mm 40-50
0.045" 45-55
1.2mm 50-60
1/16" 60-70
1.6mm 70-90
1/8" 80-100
3.2mm 90-115
3/16" 115-135
4.8mm 140-165
1/4" 160-175
6.4mm 170-200
TIG Welding is generally regarded as a specialised process that requires operator competency. While many of the principles
outlined in the previous section are applicable a comprehensive outline of the TIG Welding process is outside the scope of this
Operating Manual. For further information please refer to www.cigweld.com.au or contact CIGWELD.
HANDY HINT
Welding Amperage Rule for Stainless and Steel; for every 1mm in Thickness allow 25Amps,
e.g. 1.6mm = 40Amps | 3mm = 75Amps | 6mm = 150Amps etc

6.05 TIG (GTAW) WELDING PROBLEMS

FAULT
1 Excessive bead build up or poor
penetration or poor fusion at edges
of weld.
2 Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through.
3 Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart.
4 Weld bead too wide or excessive
bead build up or excessive penetration
in butt joint.
5 Uneven leg length in fillet joint
DC CURRENT TUNGSTEN
FOR STAINLESS ELECTRODE
STEEL DIAMETER
20-30 0.040"
25-35 1.0mm
30-45 0.040"
35-50 1.0mm
40-60 1/16"
50-70 1.6mm
65-85 1/16"
90-110 1.6mm
100-125 3/32"
125-150 2.4mm
135-160 1/8"
160-180 3.2mm
CAUSE
Welding current is too low
Welding current is too high
Travel speed too fast
Travel speed too slow
Wrong placement of filler rod
OPERATING MANUAL
FILLER ROD ARGON GAS
DIAMETER FLOW RATE
(IF REQUIRED) LITRES/MIN
1/16"
5-7
1.6mm
1/16"
5-7
1.6mm
1/16"
8
1.6mm
3/32"
8
2.4mm
1/8"
12
3.2mm
5/32"
16
4.0mm
REMEDY
Increase weld current and/or faulty
joint preparation.
Decrease weld current.
Reduce travel speed.
Increase travel speed.
Re-position filler rod.
BLUEVENOM XF190
JOINT TYPE
Butt/Corner Lap/Fillet
Butt/Corner Lap/Fillet
Butt/Corner Lap/Fillet
Butt/Corner Lap/Fillet
Butt/Corner Lap/Fillet
Butt/Corner Lap/Fillet
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