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Figure 2A-2D Welding Aluminum in the Wrong Polarity/Adjusting Balance This TIG weld (Figure 2A) was created with the machines polarity set on direct current electrode negative (DCEN). As you can see, the weld did not break through the aluminum oxide layer. This created a weld where the filler metal mixed in with the partially melted oxide and created the contaminated bead seen here. To defeat this, always TIG weld aluminum with the polarity set to
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TIG welding in AC (Figure 2B) allows the electrode positive (EP) portion of the cycle to blast away the aluminum oxide while the electrode negative (EN) portion melts the base metal. A feature called AC balance control allows operators to tailor the EP to EN ratio. If you notice a brownish oxidation and or flakes that look like black pepper in your weld puddle (Figure 2C), increase the cleaning action. However, note that Figure 2A: Aluminum welded in DC with too much EP causes the tungsten to ball excessively (Figure 2D) and provides too much etching. Lastly, argon when TIG welding aluminum, do not start welding until the puddle has the appearance of a shiny dot. This indicates that the oxide has been removed and it is safe to add filler and move forward. Adding filler to the weld zone before the oxide layer is adequately removed will result in contamination. Figures 2B and 3 Weld Graininess Figure 2B shows the way an aluminum TIG bead should look. Figure 3 shows a bead with a grainy appearance, which is typically caused by filler metal problems. For instance, a 4043 aluminum filler rod from one manufacturer may have different properties than a 4043 rod from another manufacturer. The welder (if the application permits) may need to adjust filler brand accordingly. The rod may also be defective (too much of a certain ingredient). The welder may even have the wrong type of filler rod, such as 4043 filler instead of 5356 filler. Prior to welding, always check the filler metal type and remove all grease, oil and moisture from the surface to prevent contamination. Figure 4 Lack of Fusion in the Root
Lack of fusion at the root of a T-joint or a fillet weld can be caused by a number of factors: improper fit-up, holding the torch too far away from the joint (increasing arc length) and improperly feeding the filler rod, to name a few. This issue may be seen more often with a transformer-based machine, as the arc tends to wander between the two sides of the joint as it seeks the path of least resistance. In this case, reducing arc length will provide better directional control and help increase penetration. It is also important not to under-fill the joint or weld too quickly. Note that inverter-based machines (especially those
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with an advanced output controls such as adjustable frequency and pulsing controls) offer more control over the arc. These controls create a narrower, more focused arc cone that provides better directional control over the weld puddle and deeper penetration (and often at increased travel speeds).
Figure 5A and 5B Craters Craters, such as the one shown in Figure 5A, typically occur at the end of the weld, and they often lead to cracking. Causes include instantly reducing the welding power (which causes the puddle to cool too quickly) and removing the filler rod too quickly at the end of the weld. You can easily fix crater cracking issues by continuing to feed filler rod while slowly reducing current at the end of a weld. Note that some TIG welders feature a crater control function that automatically reduces the current at the end of a weld. The result is a good-looking weld bead, as seen in Figure 5B.
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On day one of welding school, your instructor should have taught you to clean materials prior to welding. This photo (Figure 6A) shows what happens when you dont clean the mill scale off of hot-rolled mild steel. All base and filler metals need to be cleaned, whether its mill scale, oxide on aluminum, or dirt and grease on filler metals. Grind, brush and wipe away all potential contaminants. For cleaning aluminum, dedicate a stainless steel brush to the task to prevent contamination from other metals. Figure 6B shows what happens when a weld on mild steel has been properly cleaned before welding. Figure 6C shows a weld made on chrome-moly tubing that has not been cleaned, hile 6D shows a weld made that has been cleaned prior to welding.
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Figure 7A and 7B Poor Color on Stainless Figure 7A shows discoloration on a stainless steel weld caused by overheating, which not only affects a materials color, but degrades its corrosion resistance and mechanical properties as well. Unfortunately, once this error is made, there is nothing that can be done to fix it except for scrapping the part and starting over. To prevent overheating, reduce amperage, slightly increase travel speed or shorten the arc length. If your welding equipment features pulsing capabilities, now is the time to learn how to use them. Pulsing reduces heat input, and it offers excellent control of the weld puddle. Figure 7B shows proper coloration of stainless.
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Figure 10: Change in arc length For additional information on basic TIG troubleshooting, please visit http://www.millerwelds.com /resources/tech_tips/TIG_tips/troubleshooting.html
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