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sparks from tig puddle?


Tue, 31 Aug 2021 14:41:37 GMT
have been noticing something recently, doesn't happen all the time and i'm prettydarn sure hasn't happened before.. every now and again my weld puddle / arc throwingsparks.  can see them out of the corner of my eye.i'm usually pretty good about cleaning my joints (hobbyist, so no rush) and am wonderingif it wouldn't be a sign of an air leak in my torch (air getting to the puddle).thoughts?  seen this before?the only other thing that's changed is a fresh batch of filler wire, but it looks clean as a whistle.thanks.
Reply:Could be you are not keeping your weld rod in the gas stream. The tip can oxidize and burn off when you feed it into the puddle. I tend to see the little sparks when welding 4130.Is you cup clean?Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:You aren't touching the tungsten are you? >_>
Reply:I've seen it happen before. Not a clue as to what it is though.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Im very new to TIG so take this with a grain of salt but ive noticed sparks when welding over a section of steel with mill scale that hasn't been ground off.
Reply:With O/A, that means your metal wasn't clean. TIG is so similar to O/A, I bet it's that. That's what pulling your rod out of the shielding will do too, rod oxidizes which adds contaminants (O/A and TIG).
Reply:Originally Posted by DeuceTrinal That's what pulling your rod out of the shielding will do too, rod oxidizes which adds contaminants (O/A and TIG).
Reply:It's the wire, you'll really notice it on a TIG hot pass. Some brands are sparky as hell and some not. Usually when I start seeing sparks I get a little nervous about porosity, sometimes you'll find some but not always. The wire they use at our shop is real sparky, but no pinholes.
Reply:Since it started recently, check your gas. Is it 100% argon? Or did your supplier accidently give you MIG gas wit CO2 in it?Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Originally Posted by zapsterI have stated this before and here we go again...That is just a myth.Plain and simple.I have proved this time and time again but what do I know....I am not sure what his problem is but if the joint is not clean ALL THE WAY AROUND then contaminates float thru the puddle from the backside and rise to the top and make all sorts of nasty things happen.....zap!
Reply:Always happens to me when welding a36 and you hit a pocket of mill scale.Miller Dynasty 200DXMiller Spectrum 250DMiller Millermatic 200Bunch of old blue dinosaurs....
Reply:Hmmmmmm my guess would be tiny bits of metal dust that get airborne from the argon flowand then burn up=  A SPARK   Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Nothing is getting burned up in the TIG arc unless there's oxygen getting into the gas stream.  NO Oxygen = no combustion of any kind.  the OP could have a small leak in the system; something intermittent like a crack that only opens up when the torch or cable is bent in a specific way.  But it doesn't sound like this type of intermittent problem based on his description of what's going on.Sparks are momentary shorts between the tungsten and the base metal, through the argon plasma between the tungsten and the work.  It's contaminants vaporizing in the heat of the arc and then being ionized in the plasma between the electrode and the work.When you're getting sparking, are you finding that you need to change or resharpen tungstens more often?  Could you have some contamination from a past accidential dip of the tungsten in the puddle?  Something that didn't get completely cleaned off?  Have you tried a breaking off the tungsten and resharpening it from a blunt tip?  Is whatever you use for grinding Tungsten contaminated with another metal?  Did this just start when you switched to a new type or supplier of tungsten?It sounds to me like you've got some contamination either from the tungsten itself, or contamination that is not being completely removed from the tungsten when you grind it.  Or your grinding media is contaminated and you're putting contamination onto the tip of the tungsten every time you sharpen it.Try changing your grinding medium, replacing your tungsten with a new piece, and as someone else mentioned switching to a clean TIG cup.Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Gas and filler metal may be part of the problem, but in my experience the most common cause is oxidation of the base metal- rust, mill scale, plasma-cut edges, etc.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:I only see it when like mentioned mill scale comes in contact or rust or some other impurity.
Reply:Originally Posted by shovelonCould be you are not keeping your weld rod in the gas stream. The tip can oxidize and burn off when you feed it into the puddle. I tend to see the little sparks when welding 4130.Is you cup clean?
Reply:I think it might be the little specs of metal dust that heat up, and then are blown aside by the argon flow. I seen those little sparkles in the corner of my eye.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:OR......You could just weld and not worry about the sparks....  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Sparks are impurities = bad.
Reply:wow lots of good info.gas is good (same bottle).. i am running with a gas lens.. i'm sure it and the cup aren't the cleanest thing in the world.it doesn't happen all that often and yes, I usually just power through.. meaning no apparent porosity in the weld i'm leaving behind.tungsten is clean, no fondu-style dipping in the puddle.  i was just wondering if it was maybe a clear indicator of a bad torch.I'll try to keep things cleaner than usual next time and see if I can't figure out whats what.This is on an old 26 torch.. i usually (99%) run a 17.  i don't really notice it on the 17.. then againi'm not set as high (amps) as with the 26.  maybe a just coincidence.thanks again!
Reply:Originally Posted by A_DAB_will_doIt sounds to me like you've got some contamination either from the tungsten itself, or contamination that is not being completely removed from the tungsten when you grind it.  Or your grinding media is contaminated and you're putting contamination onto the tip of the tungsten every time you sharpen it.Try changing your grinding medium, replacing your tungsten with a new piece, and as someone else mentioned switching to a clean TIG cup.
Reply:The little sparks don't matter, focus on your heat input and general cleanliness.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:as i said i've only really noticed this on the 26 torch i recently had on for heavier welding.I caught said sparking on tape while filming the shop press build.You can see the fireworks show at ~24:55 in the vid link at the bottom of this.Thats the one i saw through the helment and prompted me to check the torch / ask this question.no porosity or leaking at 3000psi anyway.on closer inspection i did find a decent crack on the torch head where the insulator snaps on.  the plasticis fairly rigid but maybe when i cram the lens down trying to follow that tight radius I really open that crack up and pull in air.
Reply:Hmmmmmmmm  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:^^^^What he said.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.Originally Posted by thisoldtonyYou can see the fireworks show at ~24:55 in the vid link at the bottom of this.

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