What effect does too high of an amperage have during GTAW?

When the amperage is set too high during Gas Tungsten Arc Welding (GTAW), it leads to burn-through or excessive distortion of the material being welded. High amperage generates increased heat, which can quickly compromise the base material. This excessive heat can cause the molten pool to penetrate too deeply, leading to burn-through, especially in thinner materials. Additionally, the structural integrity of the weld can be adversely affected, resulting in warping or distortion as the materials expand and contract unevenly due to rapid heating and cooling.

In contrast, while higher amperage can enhance penetration, there is a threshold beyond which it becomes detrimental—resulting in burn-through rather than effective weld penetration. Furthermore, an inappropriate amperage setting does not lead to improved aesthetics; rather, it often results in a weld that is visually unappealing due to uneven surfaces and potential defects. The notion of increased efficiency also suffers because cycle times may increase due to the need for repairs or rework when burn-through defects occur. Therefore, maintaining the correct amperage is crucial for achieving a sound and aesthetically pleasing weld.