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PROBLEM(S)
POSSIBLE CAUSE(S)
Inconsistent /
5. MIG torch lead too long.
interrupted
6. MIG torch lead kinked or too
wire feed
sharp angle being held.
7. Contact tip worn, wrong size,
wrong type.
8. Liner worn or clogged (the most
common causes of bad feeding).
9. Wrong size liner.
10. Blocked or worn inlet guide
tube.
11. Wire misaligned in drive roller
groove.
12. Incorrect drive roller size.
13. Wrong type of drive roller
selected.
14. Worn drive rollers.
15. Drive roller pressure too high.
16. Too much tension on wire spool
hub.
17. Wire crossed over on the spool
or tangled.
18. Contaminated MIG wire.
TIG WELDING
PROBLEM(S)
POSSIBLE CAUSE(S)
Tungsten
1. Incorrect Gas.
burning away
2. No gas.
quickly.
3. Inadequate gas flow.
4. Back cap not fitted
correctly.
5. Torch connected to DC+.
6. Incorrect tungsten being
used.
7. Tungsten being oxidized
after weld is finished.
Contaminate
1. Touching tungsten into the
d tungsten.
weld pool.
2. Touching the filler wire to
the tungsten.
3. Tungsten melting into the
weld pool.
Porosity -
1. Incorrect Gas.
poor weld
2. Inadequate gas flow / gas
appearance
leaks.
and colour.
3. Moisture on the base
metal.
4. Contaminated base metal.
5. Contaminated filler wire.
6. Incorrect filler wire.
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180 MULTI-PROCESS MIG-ARC-TIG WELDER
SUGGESTED SOLUTION(S)
5. Small diameter wires and soft wires like aluminum
6. Remove the kink, reduce the angle or bend.
7. Replace the tip with correct size and type.
8. Try to clear the liner by blowing out with compressed
9. Install the correct size liner.
10. Clear or replace the inlet guide tube.
11. Locate the wire into the groove of the drive roller.
12. Fit the correct size drive roller eg; 0.030 in. wire
13. Fit the correct type roller (e.g. knurled rollers needed
14. Replace the drive rollers.
15. Can flatten the wire electrode causing it to lodge in
16. Reduce the spool hub brake tension.
17. Remove the spool untangle the wire or replace the wire.
17. Use clean dry rust free wire. Do not lubricate the wire
SUGGESTED SOLUTION(S)
1. Check that pure Argon is being used.
2. Check the gas cylinder contains gas and is connected
and the torch gas valve is open.
3. Check the gas is connected, check hoses, gas valve and
torch are not restricted. Set the gas flow between
25 to 31 CFH flow rate.
4. Make sure the torch back cap is fitted so that the o-ring
is inside the torch body.
5. Connect the torch to the negative DC output terminal.
6. Check and change the tungsten type if necessary.
7. Keep shielding gas flowing 10 to 15 seconds after arc
stoppage. One second for each 10 amps of weld current.
1. Keep tungsten from contacting weld puddle. Raise the
torch so that the tungsten is off of the workpiece 0.07 to
0.19 inches.
2. 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. Check that correct type of tungsten is being used. Too
much current for the tungsten size so reduce the amps
or change to a larger tungsten.
1. Check that pure Argon is being used.
2. Check the gas is connected, check hoses, gas valve and
torch are not restricted. Set the gas flow between 12 to 21
CFH flow rate. Check hoses and fittings for holes, leaks etc.,
3. Remove all moisture from base metal before welding.
4. Remove materials like paint, grease, oil and dirt,
including mill scale from base metal.
5. Remove all grease, oil, or moisture from filler metal.
6. Check the filler wire and change if necessary.
don't feed well through long torch leads - replace the
torch with a lesser length torch.
air as a temporary cure, it is recommended to replace
the liner.
requires 0.030 in. drive roller.
for flux cored wires).
the contact tip - reduce the drive roller pressure.
with oil, grease etc.
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