The following methods are commonly used to detect the degree of contamination of tungsten electrodes:
Visual Inspection
Use a magnifying glass or microscope to observe the surface of the electrode tip for color changes, dark spots, scale, or impurities adhering to it. When contaminated is heavy, the end often shows irregular spots or burn marks.
Microstructural Observation
Inspect the electrode surface and interior for inclusions, cracks, or other traces of contamination by light microscopy or scanning electron microscopy (SEM).
Arc Performance Test
The contaminated tungsten electrode is difficult to arc and the arc is unstable. The arc voltage and arc stability are tested through actual welding to indirectly determine whether the electrode is contaminated.
Chemical Composition Analysis
Energy spectroscopy (EDS) or spectroscopic analysis is performed on the electrode surface or abrasive chips to detect whether foreign elements (such as iron, copper, oxides, etc.) are attached or infiltrate.
Resistance Measurement
Contaminants will increase the resistance of the electrode surface, and the resistance change of the electrode will be measured by the resistance tester, which can also help determine the degree of contamination.
Weld Defect Monitoring
Abnormal defects (such as inclusions, porosity) during the welding process may be related to electrode contamination, and the electrode condition can be inferred from the non-destructive testing results.
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