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For low-amperage applications, an air-cooled torch cooled by shielding gas works well. These torches are simple to operate and require minimal setup. For high-amperage applications, you can still use an air-cooled torch, but the cable and torch must be much heavier and may be cumbersome to manipulate. A water-cooled torch, which circulates water through the torch and cable, works equally well, but requires additional equipment and maintenance. These torches use clean, de-ionized water with filters that prevent contaminants from entering the cooling supply or the inner-diameter tube of the torch. You also may need to use additives to prevent algae growth. Whether you choose a water-cooled system depends on your willingness to invest in additional equipment, as well as additional time and money for maintenance. Many welders, however, prefer these systems because the smaller torch configuration provides better maneuverability and reduces operator fatigue.
3. What are the causes of an unstable arc, and how can I remedy them?
Using the wrong size tungsten, whether in AC or DC applications, is one of the more common causes of an unstable arc. If the tungsten is too large for the amperage, the arc may rotate around the end of the tungsten. Conversely, if the tungsten is too small for the amperage, the current can melt the electrode and cause an erratic arc. To remedy either of these conditions, match your welding current to the tungsten size recommended by the manufacturer. Contaminated tungstencaused by debris on the base metal, oxidation from inadequate shielding gas, or gas impurities from a leakalso can cause an unstable arc in both AC and DC applications. To resolve this problem, replace or regrind the tungsten, make sure the base metal is clean, or increase the shielding gas flow after making sure all your hoses are intact and leakfree.
5. What are the causes and solutions for excessive electrode consumption?
Using too much current on a given application is a major cause of excessive electrode consumption and is most easily solved by increasing the tungsten size, changing the type of tungsten you are using, or decreasing the amperage. Using the wrong polarity also can result in excessive tungsten consumption. During AC welding, for example, using more electrode-positive current may provide more cleaning action, but it also subjects the tungsten to more current and thus consumption. Instead, it is best to set the power source more toward electrode negative on the balance control to minimize the amount of current and time spent on the electrode. Using an incorrect or contaminated shielding gas can lead to high electrode consumption. Be sure to use pure argon, and check for leaks in the hoses, either from cracks or loose fittings.
6. What causes porosity in a GTAW bead, and how can I prevent it?
A loose hose or torch component is a primary cause of porosity. It is remedied by tightening the fittings. If you cannot find loose hose connections by doing a visual check, you might want to place the hose in soapy water until you find the leak and tighten the fittings accordingly. Using the wrong shielding gas or one that has impurities also can lead to porosity. This is remedied by using pure argon after using nitrogen to purge the line of air and any condensation that may have accumulated. Drafts from fans or open doors also can lead to porosity, so be sure
that your working environment is well-isolated from drafts or use a gas lens to provide better gas coverage. To prevent porosity caused by inadequate shielding gas flow, follow the recommended flow rate, which is approximately 10 to 20 cubic feet per minute (CFM), depending on the application. Doing so helps ensure quality welds.
cables and work cables as short as possible, and place them close together. Physically separating your welding equipment from devices that may experience interference is also an option, but doing so can be time-consuming and space-prohibitive. If all else fails, you could switch to an inverter-based power source that provides a high frequency for arc starting only.
10. What are the cause and solution for arc rectification?
Arc rectification occurs when the surface oxide of a nonferrous metal acts as a barrier, making it more difficult for electrons to flow from the workpiece to the tungsten than from the tungsten to the workpiece. Excessive arc noise, unstable weld pools, or a weld pool that appears to dry up are all signs of arc rectification. You can either increase your travel speed or decrease the amperage for the application. Another option is to adjust the balance control on your power source toward electrode negative, which provides more penetration. As a last resort, switch to an inverter power source that offers advanced square wave technology.