Welding Tips and Tricks

I have been using an Alpha-TIG 200X for about two years without issue now but the other day it started acting up. Without changing any settings (torch negative, argon at 25 SCFH, 100 amps, 50 amp start/stop, 5 sec post flow, no pulse, DC) it began acting up badly. I was happily welding mild steel when the torch started acting like it wasn't getting gas anymore. The arc would wonder badly, the weld would pop and create massive porosity, black soot covered the weld, and the tungsten would burn up. I changed out the gas and ensured flow at the torch, I put in a new tungsten, double checked connections and grounds, cleaned everything but nothing improved the weld. Right now I've got the cover off the welder looking for burnt up caps or mosfets but everything looks normal. Has anyone else had this problem or know a solution?

Thanks,

Brian

Definitely sounds like a gas flow issue. Maybe give the gas solenoid a check while you have the machine open since you already checked the connections and swapped the cylinder.

Check your collet. If they get pinched shut they won’t flow gas.

are you sure that you're getting the proper gas flow at the torch? I was getting flow at the regulator so I assumed it was also at the torch as I could hear it. Walked over to the regulator to make sure it was set while hitting the pedal. Sat back down, hit the pedal, heard the solenoid, saw the regulator moving,,,DANGIT !!! Whats wrong, porosity and black crap. Here my stool was sitting on the lines and crimping the hose...... ... just not the CORRECT FLOW. Also, make certain the gas is the "right stuff".

What collet body, collet, cup/gas lens combination are you using? Any chance you tried replacing any of the torch parts?

FWIW, 25 CFH sounds quite high for most normal size cups/gas lenses. I was just welding mild steel with a No. 8 gas lens and maxing at 250 amps with only 15 or so CFH.

I think I found the issue, there is a hole in the gas line from the gas connection to the dinse connector. It looks like it's made of inferior rubber that just rotted away. I ordered a whole new torch with gas line/dinse connector from a different source, hopefully this one will last. It took me a while to find the issue because I could still feel and hear gas coming from the torch but it wasn't enough to cover the weld which was leading to the issues.

Ewalk02 wrote:I ordered a whole new torch with gas line/dinse connector from a different source, hopefully this one will last.

Good move Ewalk!

I have one of the Nova torches, a #26, that came with my Everlast i-Tig 201. It's one of the newer style 26 torches, so it looks like a CK Worldwide. It stops at looks though...

The red hose seems flexible like the CK Worldwide, but that's where the similarities seem to end. The hose is a Wuhan knock-off and the connectors all leave some to be desired.

I was going to replace the dinse connector, but realized it's a cheap Wuhan dinse that doesn't use a threaded fitting like the CK Worldwide dinse connector does, so it would require a barbed hose fitting, as is on it. Actually I don't think it's barbed, I think it's just a straight pipe with a pipe clamp...The reason I wanted to change the dinse is that the Everlast uses a quick disconnect and my Primeweld has a 5/8-11 connector from the dinse to the machine. I think that's a better setup, it is what Miller uses and what CK Worldwide uses on their MT200 machine. Although quick connect seems more convenient, I think it's more susceptible to leaking. I suspect that's why both Miller and CK use a threaded brass fitting.

Another user on this forum, BillE Dee, had a problem with his Everlast tig torch after a couple years where the rubber started to crack and leak, I think he had a 20 torch.

Bottom line is stick with CK Worldwide torches if you can. They cost a tad more, but the components are 1st class. My Primeweld came with a genuine CK Worldwide 17 Flexhead, with a CK dinse on it, yet another bonus to the Primeweld.

I think the writing is on the wall for my Nova 26, replace it with a CK Worldwide and don't look back. Just like all the consumables on my Everlast, they're pretty much disposable. I've replaced every single one of them, I don't have anything on it that came with the machine, including flowmeter, gas hose, ground clamp, stinger, tig torch, et al, it's easy to replace it with quality consumables and they don't cost that much. Same is probably true of your Alpha-Tig since they're owned by the same people and have the same Wuhan consumables shipped with them. I got a Lincoln ground clamp that I'm happy with. Caveat Emptor!