Whereas there are lots of methods to weld steel two items of steel collectively – fuel, stick, MIG, TIG, resistance – the one that usually strikes worry into most DIYer is TIG (Tungsten Inert Gasoline) welding. TIG welders are versatile machines that enable for welding each metal and aluminum. The method itself, nevertheless, a excessive diploma of eye-hand coordination and considered pacing as you feed filler rod right into a small weld space. However many newcomers are overwhelmed over the way to correctly arrange the welder for a venture.
Under is a primer on the essential capabilities you would possibly encounter on a typical AC/DC TIG welding machine, together with explanations of their results on the work. We’re utilizing Eastwood’s common TIG 200 AC/DC unit for demonstration functions, however the data will probably be related to different widespread shopper targeted TIG welders. At all times seek advice from your individual machine’s proprietor’s handbook for particular settings, nevertheless.
Your welder ought to have a setup information printed on a label, usually mounted in plain sight for straightforward reference. It’s vital to notice that most of the settings will present a variety, and that you could be must make changes as you’re employed primarily based on precise materials and dealing situations.
{Hardware} and Supplies
Tungsten electrode – Not like MIG or stick welding, the place the electrode is a consumable materials that melts into the weld seam, TIG welding makes use of a everlasting electrode product of tungsten. This steel’s excessive hardness together with its excessive melting level (virtually 3700º F) enable for this. Tungsten electrodes are made in numerous sizes to accommodate totally different materials thicknesses, usually both 1/16” or 3/32” for DIY welders. Thinner supplies naturally name for smaller electrodes and decrease present hundreds to stop overheating the work.
TIG electrodes are additionally coloration coded for various makes use of. The totally different colours point out totally different oxides current within the tungsten chemistry, usually thorium, cerium, lanthanum, or zirconium. The composition impacts how the electrode’s skill to hold present and resist contamination throughout welding. Pink and purple tungstens are each fairly common and stands out as the solely ones wanted for a lot of DIY initiatives.
It’s vital to notice that whereas tungsten is a troublesome materials, the precision-ground tip of a TIG electrode will erode with use. The tungsten will have to be reground sometimes to keep up efficiency. This could ideally be accomplished with a devoted tungsten grinder to take care of the fabric hardness and to stop contamination from different abrasive surfaces.
Gasoline – The kind of materials you’ll be welding will dictate the kind of inert (non-flammable, non-corrosive) fuel you’ll be flowing. Welding metal, together with stainless, requires straight argon, however aluminum requires a mixture of argon and CO2. That is usually accessible in a 75%/25% combined bottle from most welding provide outlets. Nonetheless, the 2 gasses may also be sourced individually and blended inline utilizing a regulator to manage the combination.
Gasoline lens – Because the identify suggests, these ceramic torch ends, typically known as simply cups, assist focus the fuel right into a specified weld space. The thicker the fabric, the extra fuel you’ll must stream and due to this fact a “wider” lens will probably be required. A narrower lens may also assist handle fuel stream when welding in an atmosphere with shifting air, similar to outside.
Filler – TIG welding works by including filler materials to the recent fuel arc. This filler rod materials should be suitable with the supplies being joined or welded collectively. Welding aluminum, due to this fact, requires aluminum filler rod, metal wants metal filler, and chrome steel wants stainless rod.
Management Panel Settings
AC/DC swap – Welding aluminum requires alternating present (AC whereas most different supplies use direct present (DC). It’s essential that you just set this in accordance with the fabric you’re welding.
TIG/Stick swap – This swap converts the machine from TIG operation to conventional stick welding. You’ll additionally want to maneuver the bottom clamp from the damaging port to the electrode port on the entrance of the welder and work in DC mode.
Amperage – This controls the quantity of heat-generating present going to the electrode. Thicker materials wants larger present.
Pre-flow – Earlier than you strike an arc, inert fuel must be flowing to the weld space. Pre-flow is the size of time the fuel flows earlier than amperage is utilized to begin the weld. Each hit of the set off will begin a brand new pre-flow cycle.
Publish-flow – To make sure a clear joint, the welding fuel must defend the weld space for a brief interval after the arc ends. Publish-flow is the the other of pre-flow, and the cycle must be absolutely full earlier than you pull the torch from the weld.
Clearance impact – Also called “cleansing motion,” this controls how a lot cleansing versus penetration happens which is essential to getting good penetration when welding supplies like aluminum and magnesium. A extra damaging worth will lead to higher penetration and fewer cleansing; a extra constructive worth will lead to much less penetration however higher cleansing.
Foot pedal swap – Usually you’ll management the welding cycle with the finger set off on the handheld torch. However typically you could wish to unlock your set off hand for higher management by working it with the foot pedal as a substitute.