General Welding Classifications
Following the chemical composition designation comes the letter “T” which signifies that the product is a flux cored electrode or rod. Following the “T” is a “1” or “0” indicating the recommended position of welding. The “1” or “0” following the “T” designates the following: “0” – designed to weld in the flat or horizontal position, “1” – designed to weld in all position. Following the position indicator and a dash, are the numerals “1”, “3”, “4”, “5”, or the letter “G”. The numerals “1”, “4”, and “5” identify the shielding gas required for classification of the electrode. The number “3” signifies that an external shielding gas is not employed. The letter “G” signifies that the shielding medium, chemical composition and mechanical properties are not specified.
General Welding Considerations
Titanium is a reactive metal that is sensitive to embrittlement by oxygen, nitrogen and hydrogen at temperatures above 500°F. This can be provided by shielding the metal with high purity inert gas or in a chamber. Cleanliness of the joint is a major factor in producing porosity free welds. Protection of the wire at all times is required to assure cleanliness.
Can be fusion welded to Zirconium, Tantalum, Nobuim and Vanaduim. Should not be fusion welded to Copper, Iron, Nickel and Aluminum, as it will produce extremely brittle welds.
PROBLEM:
Contact tip burn back.
​Extended Solutions for Contact tip burn back
PROBLEM:
Short contact tip life
​Extended Solutions for Short contact tip life
PROBLEM:
Erratic arc
​Extended Solutions for Erratic arc
PROBLEM:
Electrode does not feed or erratic wire feeding.
​Extended Solutions for Wire does not feed
Extended Solutions for Erratic wire feeding
PROBLEM:
Extreme Spatter
Extended Solutions for Extreme Spatter
PROBLEM:
Porosity in weld
Extended Solutions for Porosity in weld
PROBLEM:
Torch running hot
Extended Solutions for Torch or gun running hot
PROBLEM:
Liner is discolored full length
PROBLEM:
Tip disengages from retaining head
POSSIBLE CAUSE:
1.Improper voltage and/or wire feed speed.
2.Erratic wire feeding
3.Improper tip stickout
4.Improper electrode stickout.
5.Faulty ground
POSSIBLE CAUSE:
1.Improper voltage and/or wire feed speed.
2.Erratic wire feeding
3.Improper tip stickout
4.Improper electrode stickout.
5.Faulty ground
POSSIBLE CAUSE:
1.Worn contact tip
2.Buildup inside of liner
3.Wrong tip size
4.Not enough bend in gooseneck.
POSSIBLE CAUSE:
1.Feeder relay / malfunction
2.Broken control lead
3.Poor adaptor connection
4.Worn or broken switch
5.Improper drive roll size
6.Drive roll tension misadjusted
7.Burn back to contact tip
8.Wrong size liner
9.Buildup inside of liner
10. Worn drive roll
11. Improper guide tube relationship
12.Improper wire guide diameter
13.Gaps at liner junctions
14.Contact tip
​
POSSIBLE CAUSE:
1. Improper machine parameters.
2. Improper tip installation
3. Improper shielding
4. Contaminated wire or work piece
POSSIBLE CAUSE:
1.Insulator worn
2.Retaining head damaged
3.Extreme heat or duty cycle
4.Solenoid faulty
5.No gas
6.Flow improperly set.
7.Gas ports plugged
8.Ruptured gas hose
9.Control circuit loss
10. Worn, cut or missing o-rings
11. Loose fittings
POSSIBLE CAUSE:
1. Exceeding duty cycle
2.Loose or poor power connection
POSSIBLE CAUSE:
1. Short circuit to electrode
2.Broken copper stranding in power cable
POSSIBLE CAUSE:
1.Worn retaining head / diffuser.
2.Improper tip installation
3.Extreme heat or duty cycle
POSSIBLE SOLUTION:
1.Set parameters
2.See ‘Erratic Wire Feeding’
3.Adjust nozzle / tip relationship
4.Adjust torch to base metal relationship
5.Repair all cables & connectors
POSSIBLE SOLUTION:
1.Set parameters
2.See ‘Erratic Wire Feeding’
3.Adjust nozzle / tip relationship
4.Adjust torch to base metal relationship
5.Repair all cables & connectors
POSSIBLE SOLUTION:
1.Replace contact tip
2.Replace liner, check condition of electrode
3.Replace with correct tip size
4.Replace with 45° or 60° gooseneck
POSSIBLE SOLUTION:
1.Consult feeder manufacturer
2a.Test & connect spare control lead
2b.Install new cable
3.Test & replace leads and/or contact pins
4.Replace switch
5.Replace with proper size
6.Adjust tension at feeder
7. See ‘Contact Tip Burn Back
8.Replace with correct size
9.Replace liner, check condition of electrode.
10a. Replace with new drive roll
10b. Stone edge of groove on drive roll
11a.Adjust/replace guide as close to drive rolls as possible
11b. Eliminate all gaps in electrode path
12.Replace with proper guide diameter
13.Replace with new liner – be sure to measure accurately before cutting
14.Inspect & replace
POSSIBLE SOLUTION:
1. Adjust parameters.
2. Adjust nozzle/ tip relationship
3a. Verify shielding gas coverage
3b. Verify gas mixture
4. Clean wire and work piece
POSSIBLE SOLUTION:
1.Replace nozzle / insulator
2.Replace retaining head / diffuser
3.Replace with heavier consumables
4.Replace solenoid
5a.Install full tanks
5b.Check supply
5c.Check for hose leaks
6.Adjust
7a. Clean or replace gas diffuser / retaining head
7b.Clean nozzle.
8.Repair or replace cable or line.
9.See ‘Electrode Does Not Feed’
10. Replace o-rings
10b. Stone edge of groove on drive roll
11. Tighten torch & cable connections to specified torque
POSSIBLE SOLUTION:
1a.Replace with properly rated gun
1b. Decrease parameters to within gun rating
2a.Clean, tighten or replace cable grounding connection
2b.Tighten gun & cable connections to specified torque
POSSIBLE SOLUTION:
1.Isolate electrode reel from feeder and drive block. Consult feeder manufacturer’s manual.
2.Replace gun
POSSIBLE SOLUTION:
1.Replace tip and/or diffuser
2.Install as per your product Spec Sheet or Operations Manual
3.Replace with heavy duty consumables