Poor weld quality on my 200DX. Need help.

[RDK_YJ88]

Just purchased the PowerTig 200DX, after opening it up I was pleasantly surprised at how well everything looked. It was very easy to setup and get going. However once I got going, I could not get a good weld out of it. After doing some research on here, and playing with the setting for a few hours, with no luck, I decide to ask the experts. I'm not new to TIG welding, but I am new to the PowerTIG.

I'm just messing around on some 3/16 carbon steel. I'm using 3/32 2% thoriated tungsten, 3/32 ER70s-6 filler rod and I'm using the foot pedal. I'm using 100% argon with the flow meter set to 20. No argon leaks that I can hear.

Here are some pics of the welds, and my settings on the front of the machine. Any help is appreciated!

[cbmkr]

Looks like to much heat and way to much argon flow.Turn your amps down to about 110-120 , Try the argon flow at 6-7 on the gauge.

[zedron]

If you are using the gauge that came with the unit, 20 is equal to 40cfh. I would put it at 6-7 like previously mentioned. The two math it out at almost half of each other. 1cfh = .47 lpm

[Winky]

I agree too much argon ... I made the same mistake when I go my 200dx ... the meter is different to what I had been using. Also for steel use DCEN and remember the three C's and the three P's ... clean, clean, clean and practice, practice, practice. When you start doing aluminum set to AC and remember that the balance control is backwards to Miller and Lincoln with them you would set frequency around 100Hz w/ a balance around 70% ... with an Everlast set frequency @100Hz but the balance around 30% otherwise you WILL fry your tungsten and melt your cup.

[RDK_YJ88]

I turned the Argon down to 6, and the amps to 115. Still no change. I have the torch plugged into the negative side. I've been cleaning the material with a flap disk.

[zoama]

I turned the Argon down to 6, and the amps to 115. Still no change. I have the torch plugged into the negative side. I've been cleaning the material with a flap disk.

New pic of the results ?

[RDK_YJ88]

This weld is the first one I did after the changes that were suggested.




I decided to try a different piece of material to weld on and got these results. (no changes to the welder from the above results)

[RDK_YJ88]

Looks like the changes have worked. Thanks for the help guys! I still need some time getting use to the new setup, but here's my progress.

[everlastsupport]

Maybe the first piece was stainless or sumething? Looks like you are getting there now.

[Spike]

That's strange... The only throng I can think of is that the original steel was a strange alloy or contaminated deeper than the flap wheel was cleaning off... Even if it were stainless it would still weld and look okay. Maybe the tungsten was contaminated and you finally ground the messed up bit off?

[RDK_YJ88]

It was very strange. I was welding to a 4x8 sheet of 3/16 carbon steel. While welding it seemed normal, good puddle and flow, wasn't spattering or anything. But when you were done you could see all of the porosity. It may have just been the material being dirty, I suppose.

[everlastsupport]

Looks like something was cooking through it all. Maybe some junk in the cutoff wheel when you scuffed it up? If you still have, try again but run the amps up more. Or just pitch it in the scrap pile

[Winky]

It was very strange. I was welding to a 4x8 sheet of 3/16 carbon steel. While welding it seemed normal, good puddle and flow, wasn't spattering or anything. But when you were done you could see all of the porosity. It may have just been the material being dirty, I suppose.

That is strange but it looks like you’re on the right track … could be the steel you were trying to weld before had some oil of other contaminant … I didn’t see any mill scale (which frankly never gives me much issue) the steel you had at first did have a sheen to it … possibly it had nickel plating which is not great to weld and produces nasty vapor. If you start having issues again check to see that all your connections are tight, watch your angle and try to keep a tight arch … anyway … glad things are coming together.

[EchoSixMike]

Maybe some funk in the lines or regulator that's working itself out? A spray bottle of soapy water is great for finding gas leaks on fittings. A smoke machine is great too, but less available. I suppose you could try a candle, but I've never done it, I work around too many flammable materials. S/F....Ken M

[sportbike]

Looks like the changes have worked. Thanks for the help guys! I still need some time getting use to the new setup, but here's my progress.

That looks a little cleaner. A bit on the concave side, but nice rhythm and looks like your travel speed is pretty good.

[EchoSixMike]

I'd say that should be a three pass weld S/F.....Ken M

[RDK_YJ88]

I was just messing around on some scrap. Still need to get used to the bulky torch. Also need to pick up some different cups, and other consumables.

[makanik1969]

I agree too much argon ... I made the same mistake when I go my 200dx ... the meter is different to what I had been using. Also for steel use DCEN and remember the three C's and the three P's ... clean, clean, clean and practice, practice, practice. When you start doing aluminum set to AC and remember that the balance control is backwards to Miller and Lincoln with them you would set frequency around 100Hz w/ a balance around 70% ... with an Everlast set frequency @100Hz but the balance around 30% otherwise you WILL fry your tungsten and melt your cup.

I am very glad that I read this link, because I have been having some problems with practicing on aluminum. I also learned on a Miller and was setting my balance in that manner and have burned up quite a few cups and melted some Tungsten. I kept looking at my Miller cheat calculator and all I needed to do was ask Winky what the heck I was doing wrong lol. I will have to try this little tip now! Thanks Winky!

[Winky]

I am very glad that I read this link, because I have been having some problems with practicing on aluminum. I also learned on a Miller and was setting my balance in that manner and have burned up quite a few cups and melted some Tungsten. I kept looking at my Miller cheat calculator and all I needed to do was ask Winky what the heck I was doing wrong lol. I will have to try this little tip now! Thanks Winky!

You are welcome ... it was Everlast support who set me straight ... they are great!

[RDK_YJ88]

Still having fun with it!