210EXT and 325EXT Abnormal Tungsten consumption/erosion with mid/high amperage

[moltenmetal]

Sorry, it's been a bit since I followed up on this issue. I have since tried 1/8" tungsten (1.5% Lanthanated) and I continue to have the same results. The end of the tungsten never obtains a smooth ball surface, instead, it ends up with tiny balls all over the end. I never set my balance above 30, and I typically run 25 - 28. Also, if I try different wave shapes, such as Triangular or Sine, the amperage is significantly lower than in Advanced Square setting. Not sure if this is normal. This applies to my 210EXT as well as 325EXT.

[performance]

Don't ball to begin with. What you are experiencing is nodules. This can do with tungsten contamination from the metal, or with tungsten quality itself, even grinding angle and grind quality. The difference in Amperage is that the meter is calibrated to Advanced Square wave. Since the wave form is different, it reads differently even though it does reach the same level. The shape of the wave form of each is actually cooler because less time is spent at the max part of the sine wave.

[tomm]

Sorry, it's been a bit since I followed up on this issue. I have since tried 1/8" tungsten (1.5% Lanthanated) and I continue to have the same results. The end of the tungsten never obtains a smooth ball surface, instead, it ends up with tiny balls all over the end. I never set my balance above 30, and I typically run 25 - 28. Also, if I try different wave shapes, such as Triangular or Sine, the amperage is significantly lower than in Advanced Square setting. Not sure if this is normal. This applies to my 210EXT as well as 325EXT.

Sorry for posting on an old thread, but I've been dealing with the same issue with my 210ext since I bought it a couple of years ago. I was so excited to find this post showing exactly the issue I've been experiencing with my tungsten.

I've tried blue, chartreuse, and purple tungsten, 3/32 to 1/8. I grind parallel to the tip with a dedicated diamond wheel and have tried multiple wheels. I've tried a gas lens and standard collet bodies, 5 to 8 cups. I've verified the gas flow CFH at the torch with a flowmeter is 2x the cup size + 2, so if I'm running a 5 cup, I'm running 12 CFH. I've tried 20 to 40 for the balance. I've varied the frequency from 60 to 120. 1 sec pre flow and 10 post. Multiple argon bottles. I'm also welding at higher amperages, so I can't really say if it looks better at lower amperages.

Did you ever find a solution?

[performance]

What brand are you using? Quality is one factor. We see a lot of bad "batches" and variation from pack to pack, and brand to brand. Turns out quality isn't strictly controlled if you read the fine print on the documentation. Additionally, higher ranges will do that to them. Here's an article that may help: https://www.thefabricator.com/thefab...right-tungsten

But overheating tungsten, which happens at lower amperages on an inverter will cause it as well.

[tomm]

What brand are you using? Quality is one factor. We see a lot of bad "batches" and variation from pack to pack, and brand to brand. Turns out quality isn't strictly controlled if you read the fine print on the documentation. Additionally, higher ranges will do that to them. Here's an article that may help: https://www.thefabricator.com/thefab...right-tungsten

But overheating tungsten, which happens at lower amperages on an inverter will cause it as well.

Thanks for the article. Midwest and ck Lazer. As I mentioned, I tried several types and thickness of tungsten. Always get nodules, just varying degrees.