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I. Quality Control of Tungsten Rod Welding

1. Selection of Appropriate Tungsten Rod

   • The choice of tungsten rod should be based on the type, thickness, and polarity of the welding material.
   • Different welding materials require different types of tungsten rods, for instance, pure tungsten rods or nickel-tungsten alloy rods are preferable for welding aluminum.

2. Correct Grinding Method

   • Use a professional grinding machine to ensure perpendicularity between the grinding head and the tungsten rod.
   • Maintain the appropriate grinding angle and avoid excessive force that could lead to thermal deformation and compression.
   • Pay attention to the depth and frequency of grinding to prevent excessive grinding that could damage the tungsten rod due to heat.

3. Use of Shielding Gas

   • Shielding gases such as argon and helium isolate the welding area from the air to prevent oxidation and contamination.
   • When selecting shielding gas, consider the type and thickness of the welding material, and choose the corresponding gas type and flow rate.

4. Setting of Welding Parameters

   • Welding parameters such as welding current, voltage, and welding speed should be set reasonably according to the characteristics and requirements of the welding material.
   • Stable welding current and voltage can ensure the stability of welding quality.

5. Operating Skills

   • The welder should possess proficient operating skills, including maintaining the correct position and angle between the welding torch, welding wire, and workpiece, and coordinating movements.
   • During welding, maintain a stable arc with uniform arc height.
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II. Solutions to Common Issues

1. Tungsten Rod Fracture

   • Cause: Inappropriate selection of tungsten rod, incorrect grinding method, unstable welding current, etc.
   • Solution: Replace with a suitable tungsten rod, adopt the correct grinding method, and ensure stable welding current.

2. Unstable Welding Current

   • Cause: Aging or poor quality of the welding machine, faulty or insecure welding circuit, issues with the tungsten rod.
   • Solution: Replace the welding machine or repair the aged one, check the welding circuit and ensure secure connections, replace with a suitable tungsten rod.

3. Porosity in the Weld

   • Cause: Excessive or insufficient tungsten electrode extension, too fast welding speed, inadequate or moist shielding gas, etc.
   • Solution: Adjust the tungsten electrode extension to an appropriate range, choose an appropriate welding speed, increase gas flow rate, and check gas purity.

4. Weld Cracks

   • Cause: Insufficient weld size, excessive joint restraint, poor joint design and/or preparation, etc.
   • Solution: Adjust weld size according to the thickness of the part, reduce joint restraint through appropriate design, and choose a suitable joint design.

In summary, quality control of tungsten rod welding requires comprehensive consideration of multiple factors, including the selection of tungsten rods, grinding methods, use of shielding gas, setting of welding parameters, and the welder’s operating skills. For common issues, corresponding solutions need to be adopted to ensure the stability and reliability of welding quality.