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V4.2
Problem(s)
Yellowish residue /
smoke on the nozzle
& discoloured
tungsten
Unstable Arc during
DC welding.
Arc wanders during
DC welding.
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200A AC/DC Dial Control TIG Welder 202KE
Possible Cause(s)
1. Incorrect Gas.
2. Inadequate gas flow.
3. Gas nozzle too small for
size of tungsten being
used.
1. Torch connected to DC +.
2. Contaminated base metal.
3. Tungsten is contaminated.
4. Arc length too long.
1. Poor gas flow.
2. Incorrect arc length.
3. Tungsten incorrect or in
poor condition.
4. Poorly prepared tungsten.
5. Contaminated base metal.
6. Contaminated filler wire.
7. Incorrect filler wire.
Suggested Solution(s)
1. Use pure Argon gas.
2. Set the gas flow between 12 to
21 CFH flow rate.
3. Increase the size of the gas
nozzle.
1. Connect the torch to the negative
DC output terminal.
2. Remove materials like paint,
grease, oil and dirt, including mill
scale from base metal.
3. Remove 25/64 in. of
contaminated tungsten and
regrind the tungsten.
4. Lower torch so that the tungsten
is off of the workpiece 5/64 to
3/16 in.
1. Check and set the gas flow
between 12 to 21 CFH flow rate.
2. Lower torch so that the tungsten
is off of the workpiece 5/64 to
3/16 in.
3. Check that correct type of
tungsten is being used. Remove
25/64 in. from the weld end of
the tungsten and resharpen the
tungsten.
4. Grind marks should run
lengthwise with tungsten, not
circular. Use proper grinding
method and wheel.
5. Remove contaminating materials
like paint, grease, oil and dirt,
including mill scale from base
metal.
6. Remove all grease, oil, or
moisture from filler metal.
7. Check the filler wire and change
if necessary.
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