I called Miller and left a voicemail but have yet to hear back so I figured I would post up to see if any others can offer any pointers.

Setup is a Miller Diversion 180 with a 12 cup and gas lens. Usually around 25cfh for welding stainless.

Essentially the only thing I had changed was to a different type of Tungston, but after switching back to what I was using it does the same thing.

Otherwise the welder set for a day or two without being used and when I got back to welding the color hasn't been the same since. I've tried 2 other bottles of argon, new tungsten, new cup, and a older lens I had laying around that was fine when I "retired" it.

I've not only lost some color on my welds but I can't stick the tungsten out as far now when welding tight spots without it starting to ash and weld gray.

I've taken all of the hoses off and capped one end and somewhat capped the other to check for leaks with compressed air, I even took the hose off inside the case that goes from the solenoid to the welding hose and it checked out fine too.

Also not only have I noticed a difference in stainless but the aluminum is more finicky now and I had to go up to around 20cfh on it instead of the usual 15 (I run a 6 cup with no lens for aluminum).

Thanks for any help.

 

I pretty much have the same setup, I doubt it has anything to do with the welder unless for some reason your post flow is not working. You shouldn't need more then 15cfh, after that your wasting gas and the arc becomes unstable. Sounds like contamination, are you welding different material then usual? I've noticed when my welding table is right next to the welder the fan on the Diversion is strong enough to blow the gas away.

 

It's the exact same material and the welder is below the table so the fan can't blow the gas. Now that I'm moved into my new shop im going it order a new gas lens setup and see how it does. I was just waiting to get the move over with before ordering anything.

 

Contamination on the grinding wheel that you're using to sharpen the tungsten?

 

Post up a picture of the contaminated weld, how bad can it be?

 

It's doesn't look terrible, or even bad. It's just not what it was.

I've got a new lens/cup setup on the way so I'm gonna try that and go from there.

 

Sounds like bad argon. I have had several bottles in a row bad. Get a bottle from the supply out of a different fill batch.

 

We can't help diagnose a problem without a picture.

 

Check for leaks in your hose. If your tungsten is getting dark after welding, maybe bump up postflow. I usually weld with gas lens and a min of 30cfh...if it's worth welding, it's worth a little more gas to make sure I don't have to grind out porosity.

 

I agree, a leak anywhere between the bottle and the torch tip can cause what you are describing. Even though the line is pressurized, air gets sucked into the line by the passing gas. Start by checking all your fittings. It happened to me once, I just felt like my coverage wasn't as good as usual, and it was noticeable, but it wasn't horrible. I found that one fitting had become loose, and I was able to undo it with my fingers. Tightened it up and was golden.

Hope this helps!

 

gas lens...whats ur preflow and post flow.