Basic Tig Question

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Yet another new guy here trying to learn how to TIG......After a couple hours of playing with my new TIG there is one thing that I've noticed over and over that keeps on messing me up.  Quite often when adding filler to the puddle it will form as a large drop on the end of the filler rod instead of melting and flowing into the puddle.  It often times drops outside of the joint and I find myself trying to persuade it back in with the arc.  I have a feeling that it may be because my filler rod is too large for what I'm doing, but this doesn't happen every time.  It will often melt and smoothly flow into the joint just like I want it to.  I've been using 1/8" filler rod (ER70S-2 or ER70S-6, can't remember!) with the welder set at around 120 amps.  Mainly just doing corner welds trying to joint two 1/8" plates.  Would this be an appropriate time to use 3/32" filler rod instead, or is it more likely something wrong with my technique of "dipping"?
Reply:To me it sounds like way to big of filler and most likely you are feeling the filler in at the wrong angle. I have been using 1/6 filler on 1/8 plates, I would say pick up some 1/16 and some 3/32 and try them both.  As for the angle thing take a look at this http://www.millerwelds.com/education...ints_tips.htmlI was having the same problem and lowering the angle of the filler fixed it for me. -Dan
Reply:Do you have the torch angled over a lot. I noticed the same thing sometimes if I had the torch angled over a lot. Basically I was significantly preheating the filler before it got to the puddle. My problem was often the opposite in that I found smaller rods would melt faster than the larger rods.I would try to keep the torch as up right as possible. Increase your stickout a bit if you need to to see the arc. That's the primary reason I had the torch canted so much. Trying different size fillers sounds like a good idea also. I don't use 1/8" filler all that much. Mostly 3/32 and some 1/16.Good luck.
Reply:Here is another TIG resourcehttp://www.millerwelds.com/education/TIGhandbook/-Dan
Reply:Sounds like you are using the TIG arc to melt the filler onto the base metal, and then try to melt the deposit and base metal together.  This is not a good method!The basic concept of adding filler in TIG welding (and oxy/acetylene) is to melt the filler in the weld pool.  First a molten weld pool is established in the base metal, then filler is added to and melted into the weld pool.In manual welding, it is common to momentarily dip the filler into the molten puddle, retract, and dip again, repeating this dip, dip, dip, in a consistent repeatable manner.In automated TIG, the wire is commonly feed at a constant rate into the molten puddle.The concentration of arc power is best when the torch is perpendicular to the work piece, and the distance between the tungsten tip and the work is kept to a mininum, but in order to make it easier to add filler into the weld pool without hitting the tungsten with the wire, the torch is often tilted to push the puddle ahead of the tungsten a bit, and the arc length is increased a bit.
Reply:You may also be holding the filler rod to close to the arc between the dips.  Pull it back a little but not too far that you lose gas coverage on the filler rod end. That was my problem I had when it was melting.  Also try dipping faster especially with aluminum or you filler will melt away.Build a Barstool Racer at BarFlyRacers.com!
Reply:Great responses!  Looks like I need to work on my technique instead of assuming I'm using the wrong equipment.  One thing that caught my eye was in Pulser's post.  I am establishing a puddle first and then adding filler to the puddle.  However, I was typically moving the filler into the arc and letting it "drop" into the puddle.  Do I need to take the term "dip" more literally and actually stick the filler I'm adding into my molten puddle?  Thanks everyone!  Now I need some more seat time.
Reply:Originally Posted by tmorgan4 Do I need to take the term "dip" more literally and actually stick the filler I'm adding into my molten puddle?
Reply:You need .045 filler wire when using a 3/32 tungsten.. Some welding supply stores have to order it but it is worth the effort.I think they just like to hear 1/16 or 1/8 because they understand it easier than .045A filler wire that is too large will always cause problems.Your filler wire is forming a blob because it it not melting fast enough.
Reply:Another thing to keep in mind is to try to keep the wire angle low to the puddle and feed the wire on the leading edge of the puddle. Maybe 5 to 10 degrees from the surface you are welding. Let the heat on the front edge of the puddle melt the wire. There is no need to even dip it. When I walk the cup on pipe and even freehand, I very seldom dip the wire unless I am putting a root in. I will pull it out of the puddle if I have a tight groove where fusion may be a problem. I just pull it out to make sure the leading edge of the ouddle is melting the base metal underneath then go on.Have a nice dayhttp://www.weldingdata.com/
Reply:from a real poor tigger..i find that if the filler is too small, i really need to push in a lot of it to feed my pudle..if i find i have to feed a lot, i go for  the next larger  filler, or drop the heat back to slow down the melt of the rod when it hits the puddle..