The Easiest Way to Improve Weld Quality and Consistency

Parts have accumulated so much value by the time they reach the welding station that a manufacturing organization cannot afford high scrap at this operation. One of the best methods for a company to assume a superior position in the marketplace is to develop a competitive advantage by optimizing the welding process in their manufacturing environment.

Weld quality and consistency depends on consistency of input to the weld process. The Tungsten welding electrode, the source of the welding arc, is singularly the most important element of the welding system that is most commonly ignored by manufacturing organizations. Whether in manual or automatic welding, this is the area where manufacturing organizations can improve the consistency of their welding output with minor effort.

Important Tungsten Electrode Considerations

Tungsten Electrode Material Quality: Many Tungsten electrode materials are now available. The choice of electrode material type combined with the oxide size and distribution throughout the electrode have a significant effect on the quality of arc produced by the electrode. Keeping the same material type and switching to premium quality Tungsten can produce a noticeable difference in the arc and resultant weld quality. Look into the alternative materials available and investigate the differences in material quality to ensure that you are getting what your application needs.

Tungsten Electrode Grind Angle: Once an electrode tip included angle has been established for optimum weld quality it is important that this angle remain constant. Variations in this angle will have some effect on the arc shape and resultant weld penetration profile.
Tungsten Tip Flat: When a tip flat diameter has been established for the weld application it is vital that this dimension is held to very close tolerances. Minor variations in the tip flat size will have a significant effect on the resultant weld penetration profile.

Grinding Surface Finish: The surface finish of the electrode grind has an effect on the ability of the electrode to start an arc, to hold the arc stable, and the life of the electrode. Options are available for grinding surface finish. Ensure that you have the surface finish that best suits your application.

Technical Support: There are many variables in welding and sometimes welding systems seem to develop a personality of their own causing the user scrap, rework, schedule delays and pain.

There is significant technology behind the Tungsten electrode operation during arc welding in areas such as oxide dispersion and grain size, electrode oxide migration, oxide evaporation and grain growth. These properties can have significant effect on the operation of the welding system.

Our Tungsten electrode knowledge combined with our welding experience allows us to predict the most suitable electrode material, tip geometry and surface finish for a variety of applications and to help customers develop electrode specifications for their in-house use. We can also assist with arc welding parameter development and in system debug when problems arise.

Conclusion

The easiest way to improve weld quality and consistency is to improve quality right at the arc. Many manufacturing organizations are now having their Tungsten welding electrodes supplied pre-ground to specification. This is a surprisingly affordable method of guaranteeing electrode material quality, tip geometry and tolerances. We thus recommend the following options:

	Where possible use Pre-Ground electrodes from a supplier who has the necessary grinding and measuring equipment, the required cleaning and quality control techniques, and an in depth knowledge of Tungsten electrode and welding applications. Using Pre-Ground electrodes guarantees electrode and arc performance and is the best method of ensuring the optimum welding result.
	If you choose to grind your own electrodes, at the very minimum, use premium quality Tungsten electrode materials and a dedicated Tungsten electrode grinder to prepare the tip geometry.

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