What causes excessive Plasma Welding consumable wear?What causes excessive Plasma Welding consumable wear?

What causes excessive Plasma Welding consumable wear?

Causes of excessive consumable wear.

• Gas distributor inserted backwards.  Small Collar to the back of the torch.
• Improper electrode re-sharpening.  If they are sharpening their own tungsten’s they must sharpen on a tungsten grinder at a 20 degree included angle.  If the point of the tungsten is not centered it will cause premature failure of the tip.
• Tip not sized for the welding current.  Tips are rated at their maximum current capability with the electrode set flush with the end of the tip.
• Wrong welding gases used.  Must be two independent supplies.  Only use pressure regulators not regulator/flowmeters.  Set both Plasma and shield pressures to 40psi.  Argon only for the plasma gas.  If Stainless steel or titanium use a 95/5 Argon/Hy for the shield gas.  Mild steel argon for the shield gas.
• Electrode set back and plasma gas flow incorrect for the process.  Be sure they are using the setback tool provided in the parts kit when setting electrode setback.  Setback are used for keyhole process.  Melt in fusion set the electrode flush with the end of the tip.
• Coolant leak inside torch.  The 4A torch has a liner the tip screws into.  If when replacing the tip they do not support the liner from loosening they will produce a leak.
• Contaminated coolant.  Must use nonconductive coolant.  If the coolant becomes conductive consumables and torch will fail.
• Pilot arc turned on and off often and/or startup and shut down procedure incorrect.  Best to leave pilot arc on continuously through the work shift.  Before turning on the pilot purge the torch for 3 to 5 minutes.