Okay.
The other day, I was welding some 5mm aluminum (if I remember correctly). Nothing special, but my electrode kept splitting on me. I ran my welder between 60 and 120 Hz, and I dialed down my DC pre-heat as much as possible, but it didn't help much.
I exclusively buy 2% lathanated electrodes (the easy solution), and this one was a 2,4mm electrode run at 150-180 amps, with pure argon. Am I expecting too much from my electrode, and have been lucky through the years? Cause I don't think I was abusing the tungsten. Granted, I was running on Ac, but still, I was only welding 30mm beads at the time (restricted access).
My boss makes me buy consumables at our "local" welding supplier, but sometimes, I have the feeling that he deals with cheapo parts. Sometimes even the gas cups feels weird and "less nice" than what I keep at home.
So, is he giving me cheap electrodes, or am I trying to put the blame on the hardware, when I'm just pushing the limit?
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- Braehill
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That amperage range should be well within the limits of that size. I have had more than one electrode over the years that had a linear crack in it, it happens. These were all premium brands.
Len
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Len
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Now go melt something.
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Len
Instagram @lenny_gforce
Len
450dualsport
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I have been having quite a bit of trouble with this lately as well. It has been happening with 3/32 and 1/8 2% lanthanated electrodes. Both are different brands too. I have experienced this on AC as well in the same amperage range but between 100 and 150hz.
I would be very interested to hear what the cause is.
I would be very interested to hear what the cause is.
Same here. At 150+ splitting on the 3/32, but as long as I'm under 150 amps I can weld all day. Got some 1/8 in. but haven't used them yet.
I will say that I'm using a Syncro 250 and weld Alum. mostly. Settings on the penetration side,9, post flow @10 seconds.
Don't get to weld much steel, but turn to "Balanced" when I do. The amps are never as high as when I weld Alum.
I will say that I'm using a Syncro 250 and weld Alum. mostly. Settings on the penetration side,9, post flow @10 seconds.
Don't get to weld much steel, but turn to "Balanced" when I do. The amps are never as high as when I weld Alum.
dave powelson
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Breaking off the tungsten end with pliers/dykes, etc.; prior to point grinding, is a great way to induce
tight fracturing down the length. Grinding off the used end with cutoff wheel, etc. doesn't do that.
tight fracturing down the length. Grinding off the used end with cutoff wheel, etc. doesn't do that.
^ what he said. I don't know if it's a fluke, but I've had more splits with mistreatment of 2% lanthanated tungsten than other varieties. I have my best luck with grinding, or breaking off a globbed end of a tungsten using the sharp edge of a table and a hammer (as long as the tungsten is properly supported).dave powelson wrote:Breaking off the tungsten end with pliers/dykes, etc.; prior to point grinding, is a great way to induce
tight fracturing down the length.
450dualsport
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I have never broken the end off a messed up tungsten. I have always cut it off with the edge of a grinding wheel. I don't think that is the cause in my case.
The splits that I have been seeing are more like the end of the tungsten is frayed. The splits don't go up very far - maybe about a millimeter or two.
The splits that I have been seeing are more like the end of the tungsten is frayed. The splits don't go up very far - maybe about a millimeter or two.
I didn't consider that! I might have given the tungsten a knock on the edge of the table, cause I do that, when I'm in a hurry.dave powelson wrote:Breaking off the tungsten end with pliers/dykes, etc.; prior to point grinding, is a great way to induce
tight fracturing down the length.
I don't cut my electrodes in half. I keep a stock of older, shorter electrodes, that have been grinded shorter over time.Markus wrote:How do you cut tungsten before grinding? I mean when you take a new tungsten and cut it in half for example. Some grades tends to leave micro cracks when cutted wrong.
kiwi2wheels
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I think with the very variable electrode quality (rephrase that, standards ! ) these days, it would be a good idea to always mention the tungsten brand when asking about a problem. And your country.
- Otto Nobedder
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When I cut a tungsten in half, I spin it on the edge of a grinding wheel, as though I'm sharpening each end of two tungstens, until they separate. Then I "detail" each half. One end only.
Steve S
Steve S
450dualsport
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That's exactly what I do. Do you have any splitting issues?Otto Nobedder wrote:When I cut a tungsten in half, I spin it on the edge of a grinding wheel, as though I'm sharpening each end of two tungstens, until they separate. Then I "detail" each half. One end only.
Steve S
- Otto Nobedder
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Nope. Not since I began this practice. I'll have to look to see what brand I'm using.450dualsport wrote:That's exactly what I do. Do you have any splitting issues?Otto Nobedder wrote:When I cut a tungsten in half, I spin it on the edge of a grinding wheel, as though I'm sharpening each end of two tungstens, until they separate. Then I "detail" each half. One end only.
Steve S
Steve S
450dualsport
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My 3/32 tungstens are Weldcraft and my 1/8 tungstens are HTP. Both split. I think I might try some Diamond Ground next.
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kiwi2wheels
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Some years ago I asked the CKWW rep at the Essen show if their tungstens were US made or Chinese. He said CK used 3 Chinese manufacturers and CK regularly QC'd the products; I guess Boeing would not be impressed at all with sub-standard electrodes.
It could be that a brand is sourcing from several vendors................or several brands using the same vendor; how cheap can we go.
Some of the worst for splitting I found were Plansee Gold 1/16" lanthanated, cut the same way as Steve described and also with a death wheel, both spinning and stationary electrode.
Total garbage. Never had these problems with 2% thoriated and brown zirconium !
It could be that a brand is sourcing from several vendors................or several brands using the same vendor; how cheap can we go.
Some of the worst for splitting I found were Plansee Gold 1/16" lanthanated, cut the same way as Steve described and also with a death wheel, both spinning and stationary electrode.
Total garbage. Never had these problems with 2% thoriated and brown zirconium !
I ran an 1/8" all day on AC today with no splitting; switched to 3/32 at the end of the day, no splits. Running @250 amps floored on the 1/8th and 175 floored on the 3/32. The difference from my earlier experience is the grind. When I first started using 2% Lanth, I was grinding to a pencil point in an attempt to keep the puddle smaller- splits above 150 amps. Today I ground as if pure tungsten was in use- no splitting. This is in no way the answer, but time will tell.
Electrodes are from Weld City
Electrodes are from Weld City
dave powelson wrote:Breaking off the tungsten end with pliers/dykes, etc.; prior to point grinding, is a great way to induce
tight fracturing down the length. Grinding off the used end with cutoff wheel, etc. doesn't do that.
Yes ! I split the tungsten numerous times by breaking it .I use a cut off now .No more spitting.
Louie ("aka"Long Island Goomba)
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