WTH am I doing wrong here?

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I'm trying to TIG this bung in this tank.  I'm using a Lincoln Precision TIG 225 set on 90 output, pulse frequency off with post flow on 15.  I went around the whole thing and it looked pretty good.  I decided to do another pass just to church it up a bit and didn't change the settings.  Now, I can't seem to lay a clean bead to save my life.  It's like the area is contaminated.  I filled the tank with argon first.  Here's a picture.  I apologize about the quality.  The red is the reminence of the first bead, the yellow is the second.  I've ground it down and still can't seem to make it work.  Any suggestions? Attached Images
Reply:Did you touch the tunsten and not clean it?If you let it cool down completely between passes, your heat setting from the first pass might not be hot enough for the second pass.  If you dont have a good puddle going before adding filler, you get a messy ball of filler that wont fuse into the base metal.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Lol.... You are trying to weld a Hot Dip Galvanized coupler into the tank. That is your problem  Welding through thick hot dip galvanized is almost impossible... especially with TIG.You should have used a bare steel fitting... or at least ground the galvanized coating off..
Reply:Galvanized stuff will do that to ya....My name's not Jim....
Reply:Yup looks like the galvanize got you. Take a bead brush to the weld and try it again about 10-15 amps higher
Reply:It's not galvanized.  I think it just looks like that due to the wire wheel.  And, it had a pass with the grinder before hitting it with the torch.  Besides, I'd think that it would not be as pretty on the first pass around if that was the case.  I should have left well enough alone.  The plug I had in the bung was galvanized though, and I'm sure it got pretty hot.  Maybe that had something to do with it.Last edited by ARAMP1; 08-29-2010 at 10:26 PM.
Reply:Originally Posted by DesertRider33If you let it cool down completely between passes, your heat setting from the first pass might not be hot enough for the second pass.  If you dont have a good puddle going before adding filler, you get a messy ball of filler that wont fuse into the base metal.
Reply:Usually more heat or more time is needed to properly weld stainless steel as a rule if you are new to welding stainless steel. As you go with a larger bead you are going to need more heat or more time. I think Desert Rider called it. You might also try lifting the torch slightly to move, The wider fan shaped emission from the torch as you pull off, will tend to blend and melt the edges of the weld. I would try it on some scrap to get a goof feel for it. Or become comfortable with it. Normally we try to do that type of weld in one pass, no matter what. Sometimes you have to go back over the start of the weld because it is just too thin of a weld, because the part was not fully to temperature. But you try to just do one pass perfectly.        Sincerely,             William McCormick
Reply:Originally Posted by William McCormick JrUsually more heat or more time is needed to properly weld stainless steel as a rule if you are new to welding stainless steel. As you go with a larger bead you are going to need more heat or more time. I think Desert Rider called it. You might also try lifting the torch slightly to move, The wider fan shaped emission from the torch as you pull off, will tend to blend and melt the edges of the weld. I would try it on some scrap to get a goof feel for it. Or become comfortable with it. Normally we try to do that type of weld in one pass, no matter what. Sometimes you have to go back over the start of the weld because it is just too thin of a weld, because the part was not fully to temperature. But you try to just do one pass perfectly.        Sincerely,             William McCormick
Reply:any chance you nicked or kinked your gas line between passes?  It really does look galvanizing related, but if it's not galvanized then lack of gas is my next guess.  Dipped tung would be on my mind also.My name's not Jim....
Reply:It definitely looks like you touched your tungsten to the work. My next guess would be that you are pulling contaminates in from the other side or inside the joint.UA Local 598
Reply:Originally Posted by Boostinjdmany chance you nicked or kinked your gas line between passes?
Reply:Thanks gents for all the suggestions/pointers.  I'm definitely still a noob when it comes to welding (especially compared to this crowd), and having input from guys who have been there/done that is only going to make me better.  Thanks!
Reply:Originally Posted by ARAMP1 I took some brake cleaner with a small wire brush, then went over it with a rag.
Reply:Can't really tell from the picture... but are you sure that isnt a cast iron fitting??  That would explain some of your problems.
Reply:Originally Posted by wintermuteNO NO NO   Look up what happens when TIG and brake cleaner mix.http://weldingweb.com/search.php?searchid=1472708--Wintermute
Reply:WTH am I doing wrong here?You are contaminating your tungsten with filler and that's where all the funny colors come from..Looks like you actually seem to know what you are doing but stop and grind at the smallest hint of contamination..It never just goes away..Please post pics of the final decision..I'M sure some of us here would love to see a pic or 2 of the finished product.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.