How to Troubleshoot a TIG Welder

TIG welding allows small, clean weld joints on most types of metal.

A tungsten inert gas (TIG) welding machine and torch is a convenient and compact welding tool that allows for professional and clean welds on thin pieces of sheet metal. Because of its ease of use and versatility, TIG welders are popular among metalworker hobbyists and amateur mechanics. But a TIG welding machine requires maintenance and repairs on occasion. By understanding common problems and fixes for your TIG welder, you can minimize these inconvenient disruptions to your welding hobby.

Instructions

Problem: Burning Tungsten Too Quickly

1. You may have an insufficient flow of shielding gas. Your gas supply should be set between 15 and 20 cubic feet per hour (cfh).

2. You may be using improper polarity. Switch your welding electrode from positive to negative polarity.

3. You may be using a tungsten rod that is too narrow in diameter for the thickness of metal you are welding. Switch to a larger-diameter rod.

4. You may be using the wrong shielding gas. TIG welding is best performed with argon gas instead of a gas mixture or carbon dioxide.

Problem: Irregular Welding Arc

1. The alternating current (AC) frequency may not be set to the appropriate level. If the arc is too short or is not melting the metal sufficiently, you may need to increase the AC frequency.

2. If the welding arc is too long, you may be holding the tip of the torch too far from the metal. Keep the torch tip less than 1/4 inch from the metal. Be careful not to touch the tungsten tip to the metal.

3. If the arc is erratic, the tungsten tip or the metal pieces may be contaminated with carbon, paint or dirt. To resolve a contaminated tip, cut 1/2 inch of the tungsten wire off and feed a new sharp tip to the end of the torch. To clean the contaminated metal, scrape off any residual paint or dirt using a wire brush until clean metal is exposed.

Tips & Warnings

• Always wear a welder's mask and gloves while welding.

• Always weld in a well-ventilated area and away from flammable materials.

• Unplug your welding equipment before servicing it.

References

• Lincoln Electric: TIG Welding Aluminum
• Learn How to Weld: TIG Welding
• Miller: TIG Welding Tips