powerwelds

Power Welds, We've been serving welders since 2005. We know welding because We Are Welders. That's how we've curated the best products welders trust. Now our online inventory of plasma cutters, mig welding machines,tig welding machines, stick welding machines, welding helmets and welding accessories reaches hard-working welders worldwide. Thousands of products. Hundreds of thousands of customers satisfied. One goal: get you the welding equipment you need to get the job done.

All articles by: powerwelds

Website: http://www.powerwelds.com

17 May

8 Tips for Using a Plasma Cutting Machines To Improve Results

Plasma cutting machines are so easy to use that it’s tempting to take your new plasma cutting machine out of the box and go to work. However, there are a few practices that can increase your efficiency, improve your cut quality and prolong the life of your equipment.

Whether your plasma cutting machine will be used in the shop or for DIY projects, arts or motorsports, using proper techniques will deliver better results.

Learn more about choosing the right equipment as well as plasma cutting machine setup and operation.

Plasma cutting basics

Plasma provides good quality cutting, gouging and piercing at very high speeds — making this process a good fit for many industries and applications.

The process of plasma arc cutting constricts an open arc by passing it through a small nozzle from the electrode to the workpiece. Although the technology may seem complicated, the process itself is very easy to learn and perform.

The plasma process can be used on any type of electricity-conducting metal and a variety of material sizes — cutting anything from thin-gauge aluminum to stainless and carbon steel up to several inches, depending upon the power of the cutting machine.

The process also provides many benefits compared to oxy-fuel cutting. Plasma cuts faster, a pre-heat cycle is not required, the width of the cut produced is smaller and there is a smaller heat-affected zone, which prevents the surrounding areas from warping.

Keeping a few tips and best practices in mind when choosing and using a plasma cutting machine can help you improve results.

Tip 1: Choose the right plasma cutting machine

Some of the key factors to keep in mind when selecting a plasma cutting machine are output power, cutting speed, input power, duty cycle, and weight and size. Think about the jobs you will do most often when selecting your machine.

  • Output power: The necessary output power depends primarily on the thickness and type of material to be cut. Power Welds uses two standards: rated and sever cuts. A rated cut is the thickness of mild metal that an operator can manually cut at a rate of 15 inches per minute (IPM). A sever cut is the maximum thickness a plasma cutting machine can handle. The travel speed is slower, and the cut may require clean up.
  • Cutting speed: This is usually noted as inches per minute (IPM). A machine that cuts 1/2-inch material may take five minutes to do so, whereas another machine may take one. Cutting speed makes a significant difference in production time.
  • Input power: Will you always be using the plasma cutting machine in the same location, or do you need portability and the ability to use a variety of power sources? Look for plasma cutting machines that offer a range of power options. Some have the ability to switch from 110 volt to 220-volt power.
  • Duty cycle: Duty cycle is the amount of time a machine can cut within a 10-minute cycle without overheating. If a machine’s duty cycle is 60%, the machine can run continuously for six out of every 10 minutes and then needs to cool for the remaining four minutes. A larger duty cycle is important when making long cuts, in high productivity applications or when using the machine in a hot environment.
  • Weight and size: If you need portability, many hand-portable units are available that weigh less than 45 pounds. The CUT-40L plasma cutting machines provides the ultimate in portability, weighing only 22 pounds.

Tip 2: Read the plasma cutting machine manual

Thoroughly read the owner’s manual to familiarize yourself with the safe and correct operation of your plasma cutting machine. This will help you optimize your plasma cutting machine’s capabilities and also promote safe use of the machine.

Tip 3: Pay attention to setup

Secure the ground clamp to clean metal only. If necessary, grind off rust or paint, as they inhibit the flow of electricity.

Also, place the ground clamp as close to the cut as possible, or place the clamp on the workpiece itself if possible. Check your cables for worn spots, loose connections or anything that could add unnecessary resistance to electrical flow.

To set the amperage, or heat, of the cutting unit to the proper level, make a few practice cuts with the amperage set high. You can then adjust the amperage down according to your travel speed. If the amperage is too high or your travel speed is too slow, the material you are cutting may become hot and accumulate dross.

Tip 4: Trace the path before cutting

Without pulling the trigger, trace the path you plan to cut. On long cuts, practice your movements before pulling the trigger to make sure you have adequate freedom of movement to make one continuous cut. Stopping and starting again in the same spot is hard and typically creates irregularities in the cut edge.

You can also make a sample cut on the same type of material with which you’ll be working. This helps ensure you’re using the right settings and travel speed.

Tip 5: Use proper technique

Use your non-cutting hand as a support for your other hand. This steadies your cutting hand, provides freedom of movement in all directions and helps maintain a constant 1/16-inch to 1/8-inch standoff. Note that most people find it easier to pull a torch toward their body rather than push it away.

Holding a 1/16-inch to 1/8-inch standoff increases the cutting capacity of smaller machines and extends the consumables life.

Use a drag shield if your machine is equipped with one. This allows you to rest the torch on the workpiece while maintaining an optimal standoff without touching the tip to the metal, which will adversely affect cut quality and consumable life.

Begin cutting by placing the torch as close as possible to the edge of the base metal. Press the trigger to initiate the preflow air; the pilot arc will light, followed by the cutting arc. Once the cutting arc starts, move the torch slowly across the metal. Adjust your speed so that the cutting sparks emerge from the bottom of the metal. At the end of a cut, angle the torch slightly toward the end of the cut or pause briefly to completely finish the cut. The post flow air will continue for a short period after the trigger is released to cool the torch and consumable parts.

Tip 6: Check consumables

If the tip or the electrode become worn or damaged, the quality of the cut will be affected, so inspect your consumables regularly. When the tip hole becomes irregular and/or covered with spatter, discard it. When the tip of the electrode develops a pit, discard it.

The consumables will wear with each cut, but factors like moisture in the air supply, cutting excessively thick materials or poor technique will increase the deterioration of consumables. Best practice is to replace the tip and the electrode together for optimal quality cuts.

Don’t over-tighten the consumables retaining cup. The parts inside actually need to move (become separated) to create an arc, so only finger tighten the cup.

Tip 7: Watch the travel speed

The faster your travel speed (especially on aluminum), the cleaner your cut will be. When cutting thicker material, set the machine to full output and vary your travel speed. On thinner material, turn down the amperage and change to a lower-amperage tip to maintain a narrow kerf.

With a proper travel speed, the arc should exit the material at a 15- to 20-degree angle opposite the direction of travel. If it’s going straight down, it means you’re moving too slowly. If it sprays back, it means you’re moving too fast.

Traveling at the right speed and using the right amount of heat will produce a very clean cut with less dross on the bottom of the cut, as well as little or no distortion to the metal.

Tip 8: Follow plasma cutting safety procedures

Proper plasma safety requires protecting exposed skin. You’ll need welding gloves and a welding jacket or other flame-resistant clothing. Button your shirt cuffs, pockets and collar so they don’t catch sparks.

Shield your eyes with the proper shade lens for the plasma cutting machine you plan to use. The owner’s manual will state the necessary shade for the amperage. You can use traditional plasma cutting/oxy-fuel goggles or a welding helmet with a cutting mode.

Safety procedures must be closely followed in any plasma cutting application.

Optimize plasma cutting

When used properly, your plasma arc cutting unit will provide clean, quality cuts at very high speeds. Following some basic plasma cutting tips and using the right equipment for the job will help you optimize your plasma cutting for better results, increased productivity and lower operating costs.

powerwelds Welding Tips No Comments  
Read More
17 May

Learn How To Select And Operate a Plasma Cutting Machine For a Variety Of Diy Projects

Plasma cutting is not complicated. As a matter of fact, it’s a relatively straightforward process in which an electric arc is sent through a gas that’s passing through a copper nozzle with a restricted opening. The gas and arc squeeze through the opening and jump from an electrode to the material being cut.Fabricators, contractors, maintenance personnel, artists and do-it-yourselfers who experience the benefits of a hand-held air plasma arc cutting machine rarely want to return to oxy-acetylene cutting or mechanical cutting processes such as saws, cut-off wheels, shears and snips.

Many home repair and renovation projects, as well as hobbies, involve cutting metal materials. These projects may include:

  • Auto body repair
  • Metal art sculpting
  • Repairing small equipment like lawn mowers and snow blowers
  • Cutting metal studs for garages and home additions
  • Cutting gutters, down spouts, chain link fencing and clothes line poles
  • Cutting copper tubing for plumbing projects
  • Making metal lawn ornaments and holiday decorations
  • Building and repairing homemade outdoor grills

Often, home hobbyists use metal cutting shears, band saws and oxyfuel cutting torches for metal cutting. However, with new technological advances, air plasma cutting has become an affordable way to cut metal.

Air plasma cutting is a process where an electrical arc passes through a small, constricting nozzle. When a gas, usually air, is introduced, it combines with the electrical current to create a high temperature plasma arc (plasma is a state of matter, unlike solid, liquid or gas). When placed in contact with an electrically conductive material, like copper and stainless steel, the arc passes through the metal, melting a thin area. The force of the arc pushes the molten metal through the workpiece and severs the material. Although the technology behind plasma cutting may seem complicated, the process itself is very easy to learn and perform.

Plasma cutting — a cut above

Plasma cutting provides advantages over other cutting methods. It is quicker and easier than metal cutting shears and band saws. Compared to plasma cutting, shears cannot make radius cuts as tight, and saws are more expensive because they require frequent saw blade replacement, especially when cutting thicker metals.

Compared to oxyfuel torch cutting, the plasma cutting process cuts cleaner and faster and has a narrower cut width. Plasma cutting also has a smaller heat-affected zone, which prevents the surrounding area from warping or damaging paint. In addition, you can use plasma cutting on any type of electricity-conducting metal (the oxyfuel process cannot cut stainless steel or aluminum). Plasma cutting is also a less expensive and more convenient method of metal cutting because clean, dry air is used for most plasma cutting applications.

You can use the plasma cutting process to cut any material that is a good electrical conductor. It works on a variety of material sizes as well – from thin gauge aluminum to stainless and carbon steel up to several inches, depending upon the power of the cutting machine.

Setting-up a plasma cutter

To set-up, simply hook-up the plasma cutting unit to a compressed air source – available in bottles or from a small air compressor. Most plasma cutting units have their own regulator to maintain the proper flow of air for the system.

To set the amperage, or heat, of the cutting unit to the proper level, make a few practice cuts with the amperage set high. You can then adjust the amperage down according to your travel speed. Traveling at the right speed and using the right amount of heat will produce a very clean cut with little or no distortion to the metal.

Operating a plasma arc for cutting

Begin cutting by placing the torch as close as possible to the edge of the base metal. Press the trigger to initiate the preflow air; the pilot arc will then light, followed by the cutting arc. Once the cutting arc starts, move the torch slowly across the metal, maintaining a distance of 1/16″ to 1/8″ from the workpiece. All Power Welds plasma cutters have a drag shield, which lets the operator drag the torch across the workpiece while the torch tip stays the appropriate distance from the metal. Adjust your speed so that the cutting sparks emerge from the bottom of the metal.

You should be able to see the bottom of the workpiece and the arc should be directed straight down. If the sparks are not visible at the bottom of the plate, you have not penetrated the metal. Several factors can cause this: you have not properly grounded the work clamp to the workpiece; your travel speed is too fast; you have insufficient amperage; or you’ve directed the plasma stream at an inappropriate angle.

When nearing the end of a cut, angle the torch slightly toward the outside edge of the workpiece and pause briefly to completely finish the cut. The post flow air will continue for a short period of time after releasing the trigger to cool the torch and consumable parts, however you can resume cutting immediately.

Operating a plasma arc for piercing

Piercing, or creating a hole, can be performed by placing the torch at a 40-degree angle to the workpiece. Press the trigger. Once you initiate the cutting arc, bring the torch tip to a 90-degree angle and the arc will pierce the base metal. Generally, you can pierce up to 1/2 of the maximum cutting thickness provided by the machine.

What to look for in a plasma cutter for DIY use

Output Power. The output power needed depends primarily on the thickness and type of material to be cut. The metal thickness will also determine the size of the nozzle opening, as well as the type and amount of gas or air required.

Determine the type of metal you are planning to cut and then check the cutting capacity of the machine you wish to purchase. Power Welds uses three standards: rated, quality and sever cuts. A rated cut is the thickness of mild metal that an operator can manually cut at a rate of 10 inches per minute (IPM). A quality cut is rated at a slower speed but on thicker metal. A sever cut is the maximum thickness a plasma cutter can handle. The travel speed is slower and the cut may require clean up.

This type of machine works well for most fabrication, maintenance and automotive repair, as well as in hobbyist applications. A more powerful machine may be necessary for operators planning to cut thicker materials.

Cutting Speed and Capacity. Determine the type and thickness of metal you are cutting and your desired cutting speed. Then compare your needs to the cutting capacity and cutting speed of the machine you are considering.

Consumables. Besides compressed air or nitrogen, there can be as few as two consumables needed for plasma cutting. These are the torch tip and electrode. If either the tip or the electrode become worn or damaged, the quality of the cut will be affected. The consumables will wear with each cut, but factors like moisture in the air supply, cutting excessively thick materials or poor operator technique will increase the deterioration of the consumables. You will want to have consumables available when you need them, so the ability to order and receive them in a timely fashion is important. Best practice is to replace the tip and the electrode together for optimal quality cuts. It is especially convenient if the cutting machine has a storage compartment for these consumables.

Weight and Size. Weight and size may be extremely important to consider when purchasing a plasma cutter if you need portability. The CUT-40D AIR PLASMA CUTTER weighs only 10.4kg., allowing the user to carry it comfortably by its shoulder strap.

Related Products

CUT-40D AIR Plasma Cutter

CUT-40D AIR Plasma Cutter

40 AMP PLASMA CUTTER, 16MM MAXIMUM CUT, 60% DUTY CYCLE, PLASMA CUTTING – ANYWHERE, ANYTIME

The CUT-40D Air Plasma Cutter is a powerful machine that cuts through mid-steel, thin copper, thin aluminum, and stainless steel up to 16mm thick with ease, using a 220V power source. Its compact design and lightweight construction make it easy to move around, while the built-in air compressor eliminates the need for an external air supply. With a cutting capacity of up to 16mm at 40A, this plasma cutter is perfect for DIY enthusiasts and professionals alike.

The CUT-40D air plasma cutter is quick switch between built-in and external air pump and designed for maximum performance, capable of clean cutting 8mm and severing 16mm, this machine is for the professional needing maximum power from a portable machine.

Proper safety procedures

As with all industrial products, read the owner’s manual for proper safety procedures.

Closely follow safety procedures followed in any application of the plasma cutting machine. Be aware of potential hazards including high voltages and temperatures, fumes, ultraviolet radiation and molten metal. Proper welding clothing should be worn, as well as welding helmets with dark lenses or appropriate dark safety glasses, as specified by the manufacturer.

Before cutting, inspect the drag shield, tip and electrode and do not operate the unit without the tip or electrode in place. Hitting the torch on a hard surface to remove spatter can damage the torch and stop proper operation. In addition, avoid constant starting and restarting of the plasma arc to lengthen consumable life.

powerwelds Welding Tips No Comments  
Read More
16 May

How to Deal with the Challenges of Aluminum Welding in Automotive Body Repair?

With the rapid development of automotive technology, more and more body components made of aluminum materials, compared to the original carbon steel material body, aluminum body has a light weight, high safety and other characteristics, and in the repair and welding process and carbon steel material body has a very different, this article and we discuss the aluminum body welding and repair techniques to give technical support for the repair of the aluminum body.This can pose unique challenges in auto body welding.

The rise of aluminum

Corporate Average Fuel Economy (CAFE) regulations are partially driving the the industry’s move toward lighter-weight vehicles. These regulations are intended to improve the average fuel economy of cars and lightweight trucks sold in the U.S. Increasingly stringent standards recently issued by the U.S. Department of Transportation and the U.S. Environmental Protection Agency added to those regulations, requiring the average fuel economy to be the equivalent of 54.5 mpg for cars and light-duty trucks by model year 2025.

Because aluminum can be used at thinner gauges while still providing high strength, it can be used to reduce total vehicle weight and meet these requirements. The strength of aluminum, despite its thinner dimensions, helps reduce vehicle weight without sacrificing integrity or performance.

Aluminum is often used for frames and body panels, especially in larger vehicles. Today, some auto manufacturers are fabricating entire bodies from aluminum (e.g. the 2015 Ford F-150 all-aluminum-body truck). This transition makes aluminum welding a growing market in auto body repair, since these vehicles will inevitably need repairs.

Welding thin gauge aluminum like that used in many of the automotive applications poses several challenges. These issues are difficult for experienced aluminum welding operators to address and even more so for auto body technicians with no prior experience welding aluminum.

To undertake these challenges, it’s important to use equipment and consumables designed specifically for aluminum. Keep in mind some best practices that can help drive success when welding aluminum for auto repairs.

Challenges of aluminum

The main challenges posed by welding thin gauge aluminum are warping, distortion and burn-through.

Because aluminum quickly transfers heat away from the weld area, establishing the weld pool takes more energy than when welding steel. However, because aluminum has a relatively low melting point, thin sections are also especially prone to burn-through and warping. Therefore, controlling heat input during the welding process is key to addressing these issues.

Another common issue is the feedability of aluminum wire, which is softer and can be harder to feed through a gun than other filler metals. Depending on the application and the specific aluminum wire, it may be necessary to use a spool gun, push-pull gun or standard MIG gun when welding this material. Using larger diameter wires can provide more consistent wire feeding and reduce wire “birdnesting” at the drive rolls. Birdnesting is the tangling of the wire between the drive roll and the liner. Clearing it requires the welding operator to stop welding, cut the wire, discard the wire in the gun and refeed new wire through the line, which makes it a time-consuming and costly problem to address.

Auto body welding

As more auto manufacturers use aluminum in vehicles and aluminum welding in auto body repair becomes more common, shops will need to train technicians and/or welding operators who typically haven’t welded the material as to the proper techniques, power source settings and welding parameters. Those making the repairs will also need to become certified to weld on aluminum vehicles or those with aluminum components.

Auto body repair shops should also invest in new equipment specifically designed for welding aluminum.

Choosing a machine with the capability for pulsed MIG welding is critical, as this process is among the best options to control the heat input. Auto repair shops should have an aluminum-dedicated machine that is at least 230 volts and has pulsed MIG capabilities for welding 18 gauge to 1/8-inch thick aluminum. It is important to use the machine only for aluminum, as sharing it for steel welding projects, for example, can pull dust, dirt or other contaminants into the wire feeder, resulting in quality issues.

Learning proper aluminum cleaning techniques is another way auto body shops can prepare for the transition to aluminum welding. Getting the material as clean as possible and removing the layer of aluminum oxide on the surface of the material is key. This may pose a challenge in repairing vehicles that have been on the road, where dirt and gravel can become imbedded into the base material. Greater care and attention to details during the cleaning process will be absolutely essential.

When cleaning, technicians or welding operators must first use a solvent such as acetone to remove grease or other impurities. Then use a stainless steel brush to remove the aluminum oxide prior to welding.

A system designed for aluminum

When choosing welding equipment and consumables for aluminum welding, many manufacturers offer systems or welding packages designed to work together. These packages include the power source, wire, gun and other consumables, such as the nozzle, contact tip and liner.

These packages are designed as a turnkey welding solution, particularly helpful for those with limited experience welding aluminum. These systems feature simplified setup, intuitive interfaces and consistent arc performance, making it easier to execute quality repairs.

For these systems, there are some considerations when it comes to the gun. Some dedicated aluminum systems use a push-pull or a spool gun, while others, including newer ones designed for aluminum body repairs, require a standard MIG gun since auto manufacturers have specified a thicker, stronger aluminum wire for these auto repair jobs (.047 inch diameter, 5554 or 5356 alloy). Auto body shops should always consult the manufacturer for proper wire specifications and gun requirements.

For those using a standard MIG gun, it is important to use a nylon or plastic liner to help the aluminum wire slide through easier. It also prevents shaving of the soft aluminum wire, which can lead to clogs that cause poor wire feeding. A standard gun with a head tube that has a 30-degree angle instead of a 45-degree angle is a good option, as it creates less drag for more consistent wire feeding.

Recommend Aluminum Repair Equipment:

MIG-500PW MIG Welder

MIG-500PW MIG Welder

MIG-500PW |  MIG WELDER

 

The MIG-500PW MIG welders has 5m 501D water cooling MIG torch that can be set up for three different base metals (Aluminum, Brass, Stainless steel, Carbon steel and Galvanized steel). The shielding gas and weld program with the appropriate synergic curve automatically switch when pulling the trigger. The MIG-500PW MIG welder is ideal for body shops welding stainless steel, aluminum and zinc coated steel. In synergic mode, the microprocessor controls optimal arc stability and weld quality. The MIG-500PW MIG welding machine also comes equipped for MIG and MMA/stick welding. MIG and MMA welding can be done in continuous or pulse mode. The MIG-500PW MIG welding machine has a maximum power output of 500 A.

Choosing the most appropriate power source, wire, gun and other consumables are all important factors for success in welding aluminum. Choosing the right welding process is another key step.

Pulsed MIG in auto body welding

Because aluminum is such a good conductor of heat, conventional short circuit transfer isn’t a good method for welding this material. Pulsed MIG is a modified spray transfer process that is preferred and more consistent for welding aluminum.

Depending on the wire feed speed, during the pulsing process, the power source switches between a high peak current and a low background current 30 to 400 times per second. The peak current pinches off a spray transfer droplet and propels it toward the weldment. The background current maintains the arc, but because the heat input is too low, metal transfer will not occur. The peak current pulse ensures good fusion, overcoming concerns related to cold lap, a common weld defect. The background current lowers heat input, addressing the burn-through and warping issues commonly associated with spray transfer MIG welding.

Because the surrounding structure must be protected from the heat of the arc during welding, pulsing technology offers a distinct advantage in these applications. Namely, it controls heat input. As a result, a technician can make required repairs without damaging surrounding parts on a vehicle going back into service.

Tips to help ensure success

Even for experienced welding operators, welding new aluminum can pose challenges. Repair welding on aluminum on a vehicle exposed to dirt, mud, gravel and other impurities can be even more challenging.

To achieve success in aluminum auto repair applications, proper cleaning, training, and choosing aluminum-specific welding equipment and consumables are critical.

powerwelds Welding Tips  
Read More
16 May

Get Tips for Improving Results with Larger Sizes Welding Wire

In the construction of building projects, rebar has an important role in the construction of the project, and at the same time according to the different structures of the main body of the construction project, rebar construction technology also has a certain degree of variability, for this reason, through the changes in the overall shape of the rebar as well as changes in thickness, etc., to ensure the smooth implementation of the construction, which requires the relevant rebar welding technology to guide the construction, and the application of building Usually used in construction applications to larger specifications of the welding wire, the following paper will discuss these wire welding technology, so that its application in the construction of specific construction, to truly realize the quality of construction projects to improve.

Structural steel welding

Choosing the right welding wire is a crucial part of the equation in any welding application. In many construction applications, larger-diameter wire sizes are used because they provide higher deposition rates and greater productivity for welding thicker materials.

However, the higher amperage required for melting large-diameter wires can result in some challenges in welding.

Learn more about the basics of large-diameter welding wires — and get some best practices to produce high-quality welds with these wires and help minimize rework and scrap.

What are large-diameter wires?

Definitions of a large-diameter wire can vary, since some applications require using larger wires all the time. Large-diameter self-shielded wires are more frequently used on outdoor jobsites. Large-diameter solid, metal-cored or gas-shielded flux-cored wires are often used in the shop.

Many people consider any wires 1/16 inch and up to be large-diameter wires. While numerous structural fabrication applications use 5/64-inch gas-shielded flux-cored wire (FCAW-G), be aware that a wire size larger than 1/16 inch often limits out-of-position welding capabilities.

For large, thick, flat-positioned groove welds on outdoor jobsites, operators may run a 3/32-inch FCAW-S (self-shielded) flux-cored wire. You could also run a 5/64-inch FCAW-S wire for the same job and use it in vertical applications.

When are large-diameter wires used?

Large-diameter wires allow operators to put down a lot of weld metal fast. This is helpful when a high deposition rate is needed to fill deep groove welds or large fillet welds.

There are several factors that determine whether a large-diameter wire is needed. These include material thickness, weld position and joint design. For example, if you’re welding something very thick — such as a large flange-to-column connection, which may require a considerable amount of heat to penetrate it — a larger-diameter wire can take that heat without the arc breaking down.

The wire diameter that is necessary for the application typically depends on the amperage needed to weld, and the amperage needed to weld relies on the base material thickness. Put simply: the thicker the material, the bigger the wire you will need.

There are no absolutes when it comes to choosing a wire diameter, however. You may be able to make the same weld size with a 5/64-inch wire or a 1/16-inch wire if you run them at different wire and travel speeds.

Your choice also depends on the wire classification. For example, one classification of 5/64-inch wire may be used to weld out of position, while another classification of 5/64-inch wire cannot be used out of position. Part of choosing the right wire classification is knowing what positions you will be welding in. Often, the larger the wire, the fewer options it provides for running it out of position.

Addressing challenges of large-diameter welding wire sizes

Welding with larger wires typically uses higher amperages and produces a weld puddle that is larger and more fluid. This can result in some common challenges that can affect weld quality and results.

5 common challenges of welding with large-diameter wires and how to solve them:

  • Challenge: Larger weld puddle

    A larger weld puddle is harder to control and keep within the weld joint. It’s also more difficult to ensure that you’re getting proper fusion in the toes of the weld. Keep the welding arc at the leading edge of the puddle and keep a consistent puddle shape. In horizontal or vertical welds, watch for the effects of gravity and where the puddle wants to sag from the weld joint. You may have to change the gun angle to keep the puddle supported and avoid having gravity cause the puddle to sag from the joint or give uneven weld sizes.

  • Challenge: Slag entrapment

    With a larger puddle, it’s easy for slag to roll ahead of the puddle and get trapped in the weld. It’s also possible to trap slag under the weld toe if you get bead profile problems referred to as cold lap. Address this issue by watching your position in the puddle and how the puddle is fusing in at the toes to avoid rolling slag ahead of you that can get trapped. A drag technique is typically recommended with flux-cored wires. You can also adjust your work angle and travel speed to ensure you’re getting the best bead profile and puddle control. Don’t run the arc too tight: This can make the puddle flow poorly and restrict fluidity.

  • Challenge: Shielding gas flow rate

    Running large-diameter wires with a gas-shielded process means you need more gas to ensure proper coverage, since a larger, hotter puddle requires more shielding. Because this requires higher gas flow rates, operators can run out of gas faster if they’re not prepared. Be aware that you will use shielding gas faster with larger-diameter wires. Use a larger container of gas or have a supply of gas on hand that is easily available.

  • Challenge: Lack of feeder power

    Smaller wire feeders may not have enough torque at the drive rolls to push larger wires through the system. To solve this issue, choose a feeder with enough power that’s specifically designed for large-diameter wires — like the ArcReach® 16 wire feeder. Also be sure you’re using the right drive roll configuration to push the wires through. The average voltage and amperage needs of the wire will depend on the wire size and its classification. You can find those on the manufacturer’s product spec sheet. Also, be sure the machine has the duty cycle to weld at the high amperages required by large-diameter wires.

  • Challenge: Improper gun and liner sizes

    Larger wires require larger-amperage guns. An undersized gun will overheat quickly — potentially damaging the gun and requiring more downtime. In addition, liners that are the wrong size will cause feedability issues or an excessive voltage drop within the gun, affecting arc quality and consistency. Use a gun and liner that are sized appropriately for the amount of amperage and wire size you will run. Consider using a water-cooled gun to help cool down the components during high-amperage welding.

Optimizing welds with large-diameter wires

Whether on the jobsite or in the shop, welds for construction applications must meet high quality standards to pass inspection. Understanding the special considerations for using large-diameter welding wire sizes helps operators avoid issues that can lead to rework and higher costs — helping keep the project on time and on budget.

 

powerwelds Welding Tips  
Read More
15 May

TIG Welding: Definition, How it Works, How to Use, and Benefits

Tungsten inert gas (TIG) welding is a precise and versatile process used to create high-quality welds. It joins metals using a non-consumable tungsten electrode while protecting the welding area from atmospheric contamination with an inert gas such as argon. The exceptional control and versatility of TIG welding, which can join a variety of metals including copper, aluminum, and stainless steel, are its main selling points.

The method forms an electric arc between the tungsten electrode and the workpiece which produces a great deal of heat. It melts the metal while the welder manually inserts a filler rod into the molten pool to add more material. Once it cools, the pool forms a solid bond.

TIG welding has many advantages, including excellent weld quality, exact control over heat input, minimal spatter, and the ability to create welds that are pleasing to the eye. This article will examine the fundamentals of TIG welding, including how it functions, practical application tips, and its numerous advantages. Let’s dive in and learn about TIG welding.

What Is TIG Welding?

TIG welding is a precision, high-quality welding technique that uses a non-consumable tungsten electrode. The term “TIG” (tungsten inert gas) references the non-reactive gas (usually argon) employed to protect the weld area from atmospheric contamination.

What Is the Another Term for TIG Welding?

TIG welding is also known as gas tungsten arc welding (GTAW). The two names contain the same basic information: a tungsten electrode produces an electric arc to heat the workpiece while being shielded with an inert gas such as argon.

How Does TIG Welding Differ from MIG Welding?

In several ways, TIG welding is different from MIG welding. The TIG process uses a non-consumable tungsten electrode while MIG welders use a consumable electrode and a continuously fed wire. TIG welding is best for delicate applications and thin materials because it offers greater control and precision and produces cleaner welds with less spatter.

How Does TIG Welding Work?

TIG welding is a technique that joins metal parts using a tungsten electrode. An inert gas (usually argon) shields the electrode and the workpiece to prevent oxidation. The electrode and workpiece produce a high-temperature arc that melts the metal, forming a weld pool. The manually introduced filler material can reinforce the joint. For aluminum, stainless steel, and thin sheets of other metals, TIG welding offers precise control.

What Is the Primary Use of TIG Welding?

The primary use of TIG (tungsten inert gas) welding is to join metals with a high degree of precision and control. TIG welding is common in automotive, aerospace, and fabrication plants. It is especially suitable for thin materials and provides excellent weld quality with minimal distortion.

What Are Examples of TIG Welding Applications?

Examples of TIG (tungsten inert gas) welding applications include:

  1. Automotive Industry: TIG welding is used to assemble exhaust systems, fuel tanks, and engine components.
  2. Aerospace Industry: It is employed on aircraft components like engine parts, aluminum and titanium structural members, and fuel lines.
  3. Fabrication Industry: For various fabrication projects, TIG welding is used to join non-ferrous metals like aluminum, copper, and others.

How To Use TIG Welders?

To apply TIG welding effectively, follow these steps:

  1. Gather the necessary equipment: TIG welding machine, tungsten electrode, filler rod, gas cylinder, protective clothing, and welding helmet.
  2. Prepare the workpiece by cleaning it thoroughly with a wire brush or solvent to ensure a clean surface.
  3. Set up the TIG welding machine and adjust the settings to match the material and thickness.
  4. Grip the TIG torch with your hand, positioning it at an angle of around 70 or 80 degrees. Lift the torch slightly, keeping the tungsten tip 1/16 to 1/8 inch from the workpiece. Be careful not to let the tungsten come into contact with the workpiece as this can lead to contamination of the material, requiring you to regrind the tungsten.
  5. Maintain a steady hand and move the torch in a controlled manner, directing the arc along your desired weld path.
  6. Control the heat input by adjusting the amperage and filler rod as needed.
  7. Keep the torch close to the workpiece for better control and visibility.
  8. Once the weld is complete, gradually reduce the amperage and allow the weld to cool.
  9. Inspect the weld for defects and make adjustments or repairs as necessary.

When To Use TIG Welding

TIG welding is a common option when exact, high-quality welds are required. It is usually the best option for delicate seams, thin materials, and non-ferrous metals like copper, aluminum, and brass. TIG welding creates neat, aesthetically pleasing welds in a controlled manner with very little spatter.

What Are the Different Parts of TIG Welding?

The TIG welding system is composed of:

  1. Power Source: Provides electrical energy for the welding process.
  2. TIG Torch: Holds the tungsten electrode and controls the shielding gas flow.
  3. Tungsten Electrode: Forms the arc and withstands high temperatures.
  4. Shielding Gas: Protects the weld area from atmospheric contamination.
  5. Filler Metal: Optional material added to reinforce the weld.
  6. Gas Cylinder: Stores the shielding gas, such as argon or helium.
  7. Foot Pedal or Hand Control: Regulates the welding current.

What Are Some Types of Materials That Can Be TIG Welded?

TIG welding functions on a variety of materials, including:

1. Aluminum

Oftentimes, TIG welding is the optimal choice for aluminum parts. TIG equipment allows for precise control and produces high-quality welds, making it suitable for applications in aerospace, automotive, and other industries.

2. Stainless Steel

When TIG welding stainless steel, employ a DC machine to give the electrode negative polarity. The TIG torch must be connected to the negative terminal of the welder and the ground clamp to the positive terminal. Doing so gives you better control over heat input, minimizes distortion, and ensures the integrity of the stainless steel’s corrosion-resistant properties.

3. Steel

TIG welding is suitable for many types of steel, including carbon steel and low-alloy steel. It allows for precise control over heat input and produces high-quality welds with minimal spatter. TIG welding is commonly used in structural fabrication, piping, and automotive production. For more information, see our guide on Steel Metals.

4. Chromoly

Chromoly (chromium-molybdenum alloy) is a popular material in motorsports and bicycle manufacturing. TIG welding produces strong, crack-free welds that other processes can’t match on chromoly materials. TIG welding’s precise control over heat input helps prevent heat-affected zone (HAZ) issues and ensures the material’s mechanical properties are maintained.

5. Nickel Alloys

Nickel alloys, which are renowned for their corrosion resistance and high-temperature strength, are usually welded using TIG machines. Nickel alloys typically need shielding gasses like argon, helium, or a mix of the two for the best results. An alternative is to use an argon-hydrogen gas mixture designed specifically for welding pure nickel. It is appropriate for use in the power generation, chemical processing, and aerospace industries.

What Is the Hardest Metal to TIG Weld?

Aluminum can be challenging to TIG weld due to several factors. Aluminum is very thermally conductive; the heat dissipates quickly, leading to a narrow welding window. Additionally, aluminum forms an oxide layer that must be removed before welding, requiring specialized techniques and equipment.

What Is the Easiest Metal to TIG Weld?

The definitive answer is mild steel. Mild steel is widely used in construction and manufacturing because its low carbon content makes it ductile and machinable. It can be easily welded using both TIG and MIG methods, making it a versatile metal for welding applications.

What Metals Should Not Be TIG Welded?

While TIG welding is a versatile process, certain metals pose challenges and should be avoided. Reactive metals like brass and titanium have high melting points and require specialized equipment and techniques. Cast iron is also difficult to TIG weld due to its high carbon content and tendency to crack.

How Strong is TIG Welding?

TIG butt welds are typically very strong, with ultimate tensile strength reaching up to 97% of the base metal’s ultimate tensile strength. This indicates that TIG welding can effectively join components while maintaining a significant portion of their original strength.

Is a TIG Weld Stronger Than a MIG Weld?

Yes, TIG welds are generally stronger than MIG welds. TIG welding provides better penetration and control, resulting in stronger fusion between metals. TIG weld beads have fewer imperfections, which means fewer opportunities for excessive stress concentration that can lead to bigger problems.

What Are the Advantages of TIG Welding?

Advantages of TIG welding include:

  1. Precise, clean, and aesthetically appealing welds.
  2. It can be used to weld a wide range of metals, including stainless steel, aluminum, copper, and nickel alloys.
  3. Thin materials can be TIG welded thanks to precise heat control.
  4. Less post-weld cleanup is required because TIG welding produces little spatter.
  5. Strong and reliable welds with good fusion are produced by TIG welding.

What Are the Disadvantages of TIG Welding?

Disadvantages of TIG welding include:

  1. Compared to other welding techniques like MIG, TIG welding generally takes longer.
  2. TIG welding requires a higher level of skill and expertise to operate the equipment effectively.
  3. It may be challenging to weld thick materials because of the TIG process’ slow deposition rate.
  4. In comparison to MIG welding and oxyfuel welding, TIG welding supplies and equipment can be more expensive.

Can You Use a TIG Welder Without Gas?

No, you cannot use a TIG welder without gas. A shielding gas (typically argon) is essential in TIG welding to shield the tungsten electrode and the weld pool from oxygen and other atmospheric contamination. Additionally, the gas serves to cool the TIG torch, ensuring its longevity and preventing damage from overheating.

Is It Difficult To Use TIG Welding?

Yes, TIG welding is considered difficult to master. It requires a high level of coordination, practice, and skill compared to other forms of welding. The process involves simultaneously controlling the foot pedal, supplying filler material, and precisely aiming the electrode, making it challenging for beginners.

Is TIG Welding the Same as Arc Welding?

No, the terms are not entirely interchangeable. TIG welding, or tungsten inert gas welding, is a specific form of arc welding that uses a non-consumable tungsten electrode and an inert gas shield. Arc welding, on the other hand, is an overarching term that encompasses all welding processes that use an electric arc to create a weld.

What Is the Difference Between TIG Welding and Laser Welding?

The main differences between TIG welding and laser welding are:

  1. Heat Source: TIG welding heats the workpiece using an electric arc between a tungsten electrode and the workpiece, while laser welding employs a high-powered laser beam.
  2. Speed: Laser welding is typically faster than TIG welding.
  3. Precision: With a smaller heat-affected zone and greater precision, laser welding produces more compact welds.
  4. Material compatibility: While TIG welding only works with metals, laser welding is appropriate for a variety of materials, including metals and certain plastics.

Summary

This article presented TIG welding, explained it, and discussed how to use it and its benefits.

powerwelds Welding Tips  
Read More
15 May

Common Problems When TIG Welding Aluminum

When TIG welding aluminum, it can be hard to know when the puddle has been established. Learn how to address this and other common problems.

While some may consider Tig welding to be a breeze, it requires a lot of focus and experience to weld aluminum. If you’ve had trouble doing so, here are the top 10 mistakes made while Tig welding aluminum.

1 – Newbies often forget to use the high frequency setting and set it to continuous. This ends up causing the machine to stall at low amperage since the alternating current loses most of its half cycles when the flow of the current is changed. If your machine sounds like a diesel engine, you need to adjust this setting when tig welding aluminum.

2 – Incorrect electrode size is another common mistake. Amateurs may forget how hot the electrode can get at 250amps on alterative current, so they go ahead and use the same electrode on direct current. This obviously causes the electrode to malfunction and blow up! Don’t try to weld aluminum cans with a 1/8″” electrode because this will not work either.

3 – Newbies often use the wrong filler rod size. So they throw in a small filler rod which eventually makes it melt before any real welding is done. Conversely, a large filler rod can block the shielding gas and pulls the heat out of the puddle.

4 – Another Tig welding mistake to avoid like the plague is using a carbon steel brush to clean aluminum rather that a wire brush made of stainless steel. This is a basic guideline that no welder should ever forget.

5- New welders love to weld with a high torch angle. This leads to the filler metal melting and makes it in glob into the puddle. So, avoid torching at too much of an angle at all costs!

6 – Newbies, for the love of God, please don’t use too long an arc when welding aluminum. You have the find the right spot where the arc is not too close nor too far. The last thing you want is to prep electrodes rather than tig weld aluminum.

7 – Following closely with number 6, you may also overload the argon on the torch. You may be confused by various resources telling you to pump up the torch gas, but if the arc is making too much noise to the point where you think your ear drums will pop, there is too much argon flow. As a frame of reference, you need only about 13-15 cfh for a 7/16″” tig cup. More does not always mean better.

8 – Don’t follow every manual you see, especially when it comes to electrode stickout. Getting inadequate electrode stickout is another common problem. You will see Hobart training manuals recommend 1-1 1/2 electrode diameters, which is not enough. How can you be sure of your arc length if you can’t see the tip of the electrode?


9 – Although it may be tempting, do not use pure tungsten because is not efficient. Get simple 2% lanthanated if you want a comprehensive electrode that works well on alternative current and direct current.

10 – Do not ball the electrode. Just make sure that it’s round, but it shouldn’t be overly circular. A big ball at the end of the electrode will decrease efficiency, and that’s the last thing you want.

powerwelds Welding Tips  
Read More
15 May

TIG Welding Quick Tip: Introducing Filler Material to the Puddle

Recognizing weld puddle issues is crucial to ensure that you produce high-quality TIG welds. However, it is equally important to recognize when you are welding correctly. This way, you can reinforce good techniques and avoid issues in the future.

In this article, you will learn how to identify puddle issues when TIG welding and determine if you are running too hot or too cold of an arc. Additionally, we will provide some tips that are specific to TIG welding stainless steel and aluminum. By the end of this article, you will be equipped with the knowledge to improve your TIG welding skills and produce better welds.

Important Technique Requirements for Correct TIG Welding

To achieve high-quality TIG welds, you must follow several essential technique prerequisites.

  • First, get into a comfortable body position over the welded piece to achieve good hand mobility and stability.
  • Second, maintain a smooth torch travel, and use the correct torch angle for the joint type.
  • Third, apply a consistent arc length and foot pedal control.
  • Fourth, one hand moves the torch, and the other feeds the filler material.
  • Fifth, ensure sufficient shielding gas coverage to avoid contamination.
  • Sixth, avoid dipping the tungsten into the weld puddle, moving the filler material outside of the shielding gas zone beneath the cup, and touching the tungsten tip with the filler metal as you weld.
  • Finally, don’t use a thicker filler wire than the welded material. Violating any of the essentials listed above will cause puddle control issues and reduce, if not outright ruin, the weld quality.

Recognizing The Correct Amperage Input

When TIG welding, using the correct amperage input is crucial to achieve quality welds. Applying too much or too little heat can cause puddle control issues, poor penetration, warping, and burning through on thinner metal. Therefore, it’s essential to recognize if you need to back off the amperage or increase it. Here are some signs that will help you recognize if your weld puddle is too hot or too cold.

Weld Puddle Is Too Hot

If your TIG welder is outputting too much amperage for the welded material thickness, you will experience the following issues:

  • Shaky puddle – It’s normal to experience a little bit of an unsteady and wobbly molten puddle surface. But, if your weld puddle is too shaky and experiences high trembles, it won’t be easy to direct and control.

  • Too wide heat-affected zone (HAZ) – Inputting too much heat when TIG welding causes a wide HAZ, risking warping and oxidation damaging the welded material, especially on stainless steel.

  • Oxides buildup in the weld pool – You may also experience oxides building up in the weld pool depending on your shielding gas coverage and travel speed.

  • Weld pool pulls contaminants into itself – If you didn’t clean the material upfront properly, running your TIG welder too hot will pull more mill scale into the weld pool and other contaminants.

  • Undercut – Using too high amperage will cause undercutting, especially when making a fillet weld. High heat will erode the upper part of the fillet joint and cause undercutting, which weakens the weld.

  • Puddle is melting through – If the puddle falls through the edges of the joint, you are using too many amps.

To avoid these issues, reduce the amperage input and adjust the heat control. Ensure sufficient shielding gas coverage and keep the filler material within the shielding gas zone beneath the cup. Don’t dip the tungsten into the weld puddle, and don’t touch the tungsten tip with the filler metal as you weld.

Weld Puddle Is Too Cold

On the other hand, beginner TIG welders are often afraid of warping and burning through the thin material. So, it’s a common mistake to use too low amperage. However, this fear is rational. It’s easy to burn through and distort thin sheet metal, especially stainless steel. Here are some signs that indicate that you have reduced amperage output too much and that increasing it will help:

  • Forming the weld puddle is too slow – If the base metal melts too slowly, you are doing more harm than good by concentrating the arc into one spot for a prolonged period.

  • Filler material won’t melt in the weld puddle – If you dab the filler wire into the weld puddle and it won’t fully melt, increasing amperage output may help.

  • Poor puddle fluidity – Unlike the shaky, wobbly puddle made with too much heat, the low heat input will create a small puddle that barely consumes the base metal and moves slowly.

  • Poor penetration – Using too low amperage output results in poor joint penetration and fusion, making a weak bond.

To avoid these issues, increase the amperage input and adjust the power setting. Ensure sufficient shielding gas coverage, and keep the filler material within the shielding gas zone beneath the cup. Don’t dip the tungsten into the weld puddle, and don’t touch the tungsten tip with the filler metal as you weld. Use the correct travel speeds, arc length, and DCEN or DCEP polarity, depending on the material thickness and type. Consider using inert gases such as argon or helium for better penetration and cleaner welds.

Remember, recognizing the correct amperage input is crucial for achieving quality TIG welds. By reading the puddle and adjusting the heat control, you can avoid puddle control issues, poor penetration, warping, and burning through on thinner metal.

Puddle When Welding Dirty Material

When welding dirty material, it is essential to clean the surface from mill scale, oxides, paint, oils, and other contaminants to achieve a quality TIG weld. Failure to clean the material properly can lead to various weld puddle issues, including porosity, bubbles, smoke, and poor, brittle welds. Some signs that the material needs more cleaning include debris forming on the solidifying weld puddle and uneven ripples of the TIG welds. To avoid these issues, make sure to clean the material thoroughly before welding and use proper techniques to prevent dirt and other contaminants from affecting the weld quality.

Stainless Steel

Stainless steel is a unique material that requires special attention when welding. Due to its poor heat conductivity, stainless steel retains heat very well, which can cause it to oxidize and go through carbide precipitation if held at high heat for prolonged periods. As a result, it is essential to control heat input when welding stainless steel to avoid destroying its corrosion resistance.

To ensure a successful weld, the weld puddle shouldn’t be more liquid than necessary, and the heat-affected zone (HAZ) should be as narrow as possible. Using a sharp tungsten tip and ensuring good shielding gas coverage is also crucial. High welding speed is preferred to avoid heat concentration in one area for too long, but do not use too low heat input either. The puddle must be fluid but not too runny.

It is important to note that stainless steel requires a different approach than mild steel.

Remember to take proper precautions when welding stainless steel to avoid damaging the material and ensure a successful weld.

Aluminum

Aluminum is a notoriously difficult material to weld, thanks to its oxide layer. But, this metal has another issue: excessive heat conductivity. So, unlike stainless steel, aluminum is very good at dissipating heat.

To weld aluminum, you need to use a much higher amperage than to weld stainless steel. Otherwise, the puddle will be unresponsive and not liquid enough. That’s because the aluminum will dissipate the heat input from the arc into the HAZ and surrounding metal, and there won’t be enough power left to keep the weld puddle liquid.

However, as aluminum gets hotter, you may need to back off the foot pedal to reduce the amperage input. If the puddle turns too wide and becomes uncontrollable, reduce the power input.

Aluminum Oxides

To weld aluminum, you must use an AC TIG welder because the DCEP part of the current is responsible for cleaning the aluminum oxides on the surface. The other part, DCEN, achieves the necessary penetration, melts the material, and fuses the two pieces together.

However, it’s important not to start adding the filler wire and moving the torch until the DCEP cleans the initial puddle. When you initiate the high-frequency arc, you need to wait for a brief moment until the puddle looks like a shiny dot, and only then start moving the torch and adding the filler material.

The initial puddle becomes shiny because the DCEP has burned the oxide, and now the pure aluminum underneath is ready to be bonded with the filler metal.

If your AC balance setting is too shallow, the DCEP won’t have much cleaning power. This can result in more oxide inclusion in the weld and make a poor joint. Keep an eye out for any debris floating in the molten aluminum puddle.

In summary, to weld aluminum, you need to use a higher amperage, and an AC TIG welder is necessary to clean the aluminum oxides on the surface. Be patient and wait for the initial puddle to become shiny before moving the torch and adding the filler material. Keep an eye out for any debris floating in the molten aluminum puddle.

Power Welds TIG Welders Collection

TIG-400PI AC DC TIG WELDER

 

TIG-400PI AC DC TIG Welder

TIG-400PI AC DC TIG Welder

The TIG-400PI AC/DC TIG Welder gives you maximum control over High-Frequency AC/DC TIG welding for incredible results from start to finish, and the minimum AC current can be 10A, ensuring optimal welding performance of thin aluminum sheet.

This 3 Phase machine is capable of different shapes of welding, like butt-joint, corner joint, T-joint, lap joint, and cruciform joint

Industrial purpose IGBT dual-module and heavy-duty cycle, TIG-400PI AC/DC TIG Welder is a complete and professional TIG /STICK welding machine that is ideal for all high-end aluminum, stainless steel fabrication, marine, and industrial engineering welding situations.

1. Multi-function welding – AC TIG, AC pulsed TIG, DC TIG, DC pulsed TIG, MMA and Auto welding.
2. Industrial purpose IGBT dual-module and heavy-duty cycle.
3. Minimum AC current can be 10A, ensuring optimal welding performance of thin aluminum sheet.
4. High frequency arc start with high success rate.
5. Adjustable clean width and clean scope.
6. Intelligent over-voltage, low-voltage, over-current and over-heat protection, safe and reliable.
7. Capable for different shapes welding, like butt joint, corner joint, T-joint, lap joint and cruciform joint.

Conclusion

TIG welding is a highly advanced welding process that requires a lot of skill and practice to master. One of the most challenging aspects of TIG welding is recognizing and addressing puddle issues in real-time. This requires a keen eye and a deep understanding of the welding process.

Although observing the puddle is important in MIG and stick welding as well, it is much harder to do so due to the smoke and nozzle obstruction. In TIG welding, there is very little room for error, and any issues with the puddle must be addressed immediately.

With practice, you can develop the necessary muscle memory to master TIG welding. By controlling the heat input, travel speed, and recognizing the puddle cues, you can create fantastic TIG welds and tackle even the most challenging welding jobs.

In conclusion, mastering TIG welding takes time and effort, but with the right approach and mindset, you can become a skilled TIG welder and produce high-quality welds.

Frequently Asked Questions

How to Identify an Ideal TIG Welding Puddle Size?

To identify an ideal TIG welding puddle size, you need to ensure that it is not too big or too small. A good puddle size is typically about the size of a dime or a quarter. The puddle should be evenly distributed and should not have any irregular shapes. If the puddle is too small, it can lead to a weak weld, whereas a large puddle can cause the metal to warp or burn through.

What Techniques Are Used for Maintaining Puddle Control in TIG Welding?

Maintaining puddle control is crucial for successful TIG welding. Some techniques that you can use to maintain puddle control include:

  • Adjusting the amperage and travel speed
  • Using a foot pedal to control the amperage
  • Keeping the torch at a consistent angle
  • Using filler rod to add material to the puddle
  • Keeping the torch close to the workpiece

Is It Better to Push or Pull the Puddle in TIG Welding, and Why?

It is generally better to pull the puddle in TIG welding. Pulling the puddle allows you to see where you are going and helps you maintain control. Pushing the puddle can cause the weld to become distorted or even break. Additionally, pulling the puddle allows you to maintain a consistent travel speed and angle, which is crucial for a stable weld.

What Are the Characteristics of a Stable Weld Puddle in TIG Welding?

A stable weld puddle in TIG welding should have the following characteristics:

  • Evenly distributed
  • Consistent in shape and size
  • No irregularities or cracks
  • No porosity or pinholes
  • No discoloration or burnt spots

How Does Puddle Shape Affect the Outcome of a TIG Weld?

Puddle shape can have a significant impact on the outcome of a TIG weld. A puddle that is too wide or too narrow can cause the weld to become distorted or even break. Additionally, a puddle that is too shallow can lead to a weak weld, whereas a puddle that is too deep can cause the metal to warp or burn through.

What Are Common Mistakes to Avoid When Learning Puddle Control in TIG Welding?

Some common mistakes to avoid when learning puddle control in TIG welding include:

  • Moving the torch too quickly or too slowly
  • Not maintaining a consistent travel speed or angle
  • Using too much or too little filler rod
  • Not adjusting the amperage or travel speed correctly
  • Not keeping the torch close enough to the workpiece

By avoiding these mistakes and practicing good puddle control techniques, you can improve your TIG welding skills and create high-quality welds.

powerwelds Welding Tips  
Read More
15 May

When to Use Pulse TIG for TIG Welding

TIG welding with the pulse TIG feature is most often done for thin metals such as aluminum and can also be used with copper and varieties of steel. Pulsing can be set up with a foot pedal or as a setting on your TIG welder, but when should you use pulsing? There are some very specific applications for pulsing with a TIG welder and then there are times when it can just come in handy to get a job done better. Here’s a look at some TIG welding with pulse applications:

Greater Control Over the Heat

Pulse for TIG is all about improving your control when you don’t want to burn through your metal workpiece. Using the pedal or setting up the pulse will moderate the heat as you weld and ensure you have enough heat present at the joint without laying a ton of filler metal into the joint or burning through the metal.

Too much metal in the weld joint could create a headache for your welding project, as you’ll have to stop to grind it down and then clean up the metal before you can start welding again. The pulse setting gives you far more control over the welding process without compromising the strength and integrity of your weld.

When You Need a Neat Weld

Pulsing your weld is an easy way to create a smooth, clean weld for a TIG welding application. Getting yourself in a steady pulsing rhythm is an ideal way to keep moving the puddle forward or walking the cup along a weld joint

TIG welding is most often used when there is little margin for error and the metal is especially thin. By pulsing along the weld joint you can moderate the amount of filler metal you add so that it’s evenly distributed and you create a great looking weld.

Minimal Movement

If you’re in a tight spot and you don’t have a lot of room to maneuver, pulsing your TIG welder is one way to glide along the weld joint, adding filler metal as you go, without worrying about introducing too much heat and filler. The main thing for this application will be a steady hand on the torch and an even pace for the filler metal.

If this is a particularly tight spot, you can pick up shorter torches that have a very small head and can fit in a variety of spaces. With TIG welding you can reach a tight spot much better than with a stick welder and you can control the input of filler metal better than with MIG, making it a great option when welding is particularly challenging.

Moving Faster with High Speed Pulse

Given some practice, many welders can effectively weld at the high speed of 150 pulses per second, creating neat welds in far less time. While you wouldn’t want to try a faster pulsing speed if you’re not used to it, many welders prefer to move either really slow or really fast in order to create a steady rhythm. Pulsing at around 20 per second has led some welders to make uneven, spotty welds.

This would be especially useful in a fabrication shop where you’re seeing a lot of the same metal work pieces over and over and over again. If you have a handle on how fast you need to move on each piece, then there’s a good chance you can bump up the pulsing rate to improve your welding speed.

Welding Along an Edge or a Hole

If you need to make a quick clean weld without ruining an edge or filling a hole with filler metal, pulsing is another great way to give yourself extra control and accuracy in a difficult welding position. The heat could build up and start to melt the metal if you don’t have a good steady pulse going while you TIG weld.

powerwelds Welding Tips  
Read More
14 May

The Five Welding Tips & Tricks for TIG Welding Pipes

If you want to get a welding job using TIG welding, one of the skills you should add is welding a root pass on a pipe. Pipe welding is common in a variety of industries that are seeing significant job growth, and TIG welding is specialized enough that you can land a great welding job if you practice your technique and get the proper welding certification. Here are five tips on how to develop your TIG welding skills for a pipeline.

Learn to Walk the Cup While TIG Welding

When you’re welding around a pipe for a root pass, there may be times when it’s possible to walk the cup. This calls for a steady hand as you move the electrode and use the TIG cup to provide additional stability. Walking the cup should also give you a much cleaner, more uniform weld. While there may be times when you’ll have to freehand your pipe welds, you’ll always be glad you learned to walk the cup.

Travel Forward and Back While TIG Welding

The forward and back motion will be more effective when you’re walking the cup with the electrode for a root pass on a pipe because it will provide deeper penetration into the metal. The forward motion will help the filler metal go deeper into the weld joint, while the backward motion will provide additional heat to help it settle in. Side to side won’t provide the same heat and penetration that you’ll need to make a clean, strong weld on a root pass.

Run Your TIG Welder Hot

While you can certainly distort your metal if you run your TIG welder too hot, don’t be afraid to run your welder hot enough to break down the edges of the work piece in order to get good, strong fusion with the welding material. Running too cool will result in a weak weld, so the key to welding effectively is learning how to weld with plenty of heat  without damaging your materials. It’s important to get enough penetration during the root pass, and heat is the key.

During the root pass you’ll also run your filler metal along the weld joint and keep it there rather than dipping it in and out. This ensures you’ll get enough material in on the first pass.

Keep It Hot for the Hot Pass

If you’re already working at a good, hot amperage for your root pass, you can use the same settings for your hot pass. Don’t crank it too hot, or you’ll have a mess on your hands!

Stack Your Weld Beads

When you add your additional passes along the pipe, you can weave your welds in like any other weld joint. Welders typically use either a series of cursive e’s or a kind of side to side arc. During these passes you’ll want to crank up the heat a little bit more. Rather than running your filler metal along the weld joint like your first pass, you’ll dip it in and out to make sure you don’t dump too much filler into the weld joint.

powerwelds Welding Tips  
Read More
14 May

How to Choose the Best TIG Welding Gas for TIG welding

In TIG Welding of Carbon Steel, Stainless steel, Aluminum, Copper, and Nickel Alloys, we use only inert gases such as Argon (Ar) and Helium (He) and they are the main welding shielding gases for TIG welding of stainless steel, aluminum, carbon steel, copper alloys or any other material. These gases are inert gases and either they are used as single components or mixed components (E.g. Argon + Helium mixture) & as a Tri-mix welding gas for special applications.

Welding shielding gases are used to protect the weld from contaminants in the atmosphere. The most common shielding gas is argon, which is inert and does not react with the weld metal. Other shielding gases include helium, carbon dioxide, and nitrogen. Helium is used for welding aluminum because it has a lower melting point than argon. Carbon dioxide is used for thick steel plates because it provides good penetration.

A small quantity of Oxygen (O), Nitrogen (N), and Hydrogen (H) are sometimes added in argon or helium to give special characteristics to the welding gas for TIG welding of stainless steel, duplex stainless steel, Titanium or copper alloys.

Before we learn about each type of welding gas, let us first see what is meant by Inert Gas in Welding Gas terminology.

What is an Inert Welding Gas & why are they used in Welding?

Inert Welding Gas means that there is no reaction between the molten welding pool and the shielding gas. Argon or Helium if used for welding gas shielding or purging, the weld pool will not react with these gases to make their oxides.

Difference between gas shielding, gas purging & gas trailing?

For example, if Oxygen is used for shielding, oxygen will react with elements to make their oxides such as manganese oxide or silicon oxides. Thus precious alloying elements will be lost. But when using inert gases, these elements are preserved in the weldment without any losses and the weld also exhibits a high surface finish.

Argon being an inert gas is monatomic gas (i.e., its molecule consists of one atom instead of two atoms in the case of common gases like oxygen, nitrogen, chlorine, etc.). Argon is taken out from the earth’s atmosphere by air liquefaction to make it 99.99% purity. It is supplied as compressed gas in cylinders or as a liquid at temperatures below —184°C in large insulated containers. For bulk storage, the latter form is preferred, but suitable equipment must be provided to vaporize the gas for distribution on the shop floor.

Welding gases Classification System

Welding gases for shielding or purging applications are classified in AWS A5.32 specification and ISO 14175 standard for shielding gases.

What Welding Gases for TIG Welding of Stainless Steel?

Argon Welding Gas for TIG Welding of stainless steel, carbon steel, Aluminum

Argon is the most used TIG welding (GTAW) gas worldwide. The AWS A5.32 classification of pure argon is SG-A with a minimum purity level of 99.997%, maximum moisture of 10.5 ppm and maximum dew point moisture at 1 atmospheric is −76°F.

The ISO 14175 designation for pure argon is ‘I1‘. Pure argon is inert in nature and will not react with tungsten rods and weld metal. Due to the high density of argon, the shielding blanket is very effective to protect the weld pool from oxidation.

The welding arc ignition properties with argon gas are good because of the low ionization of the argon and hence it requires low welding voltage.

Helium Welding Gas for TIG Welding of stainless steel, carbon steel, Aluminum

Helium is an inert welding gas. As most of the stainless welding requires low heat input to ensure control of austenitic phases & helium gives high heat input in Welding, Pure helium is not used for welding stainless steel with TIG. Pure helium as a welding gas is mainly used for welding of copper, magnesium, and aluminum TIG Welding.

It is usually mixed with argon as a minor gas component. Helium is having low density compared to argon and hence it requires a higher shielding gas flow rate.

Pure helium supports globular transfer mode & it must be mixed with a minimum of 20% argon to support spray transfer mode in welding.

Argon-Helium Welding Gas mixture for TIG welding of stainless steel, carbon steel, Aluminum

AS stated, pure helium is not used for TIG welding of stainless steel & it is mixed with argon to make an effective welding gas for TIG Welding. SG-AHe-10 gas classification as per AWS A5.32 is an example of such a gas mix used for stainless steel welding. Mainly higher helium mixtures (Such as SG-HeA-25) are used for TIG welding of copper.

When helium is added to the shielding gas, the voltage required for welding is higher. Hence, there is an increased arc temperature. This results in deeper weld penetration.

Argon-Hydrogen Welding Gas mix for TIG Welding of stainless steel, carbon steel, Aluminum

Hydrogen being a reactive welding gas is limited as a minor gas component in small quantities only i.e. usually 1 to 5% when welding stainless steel. The addition of hydrogen is beneficial to enhance the welding speed as hydrogen increases the welding heat input.

Hydrogen also provides reducing effects in weldment to eliminate oxygen from a weld that can reduce weld toughness.

These gas mixtures are used only for welding Nickel base alloys or austenitic stainless steel. Hydrogen, if used for ferritic or martensitic base materials, can result in hydrogen cracking. Examples of AWS A5.32 classification for Argon-Hydrogen welding gas are SG-AH-1 & SG-AH-2.

Argon-Nitrogen Welding Gas mix for TIG Welding of stainless steel, carbon steel, Aluminum

Argon-Nitrogen Welding gas mixtures are used mainly for welding Duplex & Super Duplex Stainless Steel Welding (Chrome-Nickel Steel). Nitrogen being a strong austenitic stabilizer is mainly used for welding Duplex & Super Duplex Stainless Steel to maintain the Austenite & Ferrite Phase balance in the weld microstructure.

The AWS A5.32 classification for Argon-Nitrogen mixture is SG-NH. SGNH-2 Is the most used welding gas classification for this category.

Welding Gas Chart for TIG & MIG Welding

Welding Gas Chart for TIG & MIG Welding for Carbon Steel, Stainless Steel, Duplex Stainless Steel, Nickel Alloys, and Aluminum Alloys are given below for reference purposes. Refer to actual Qualification WPS to meet Welding Gas requirements.

Welding Gas Carbon Steel 300 Series Steel 32205, 1.4462 (Standard Duplex Steel) 32520, 32750 (Super Duplex Steel) Ferritic
stainless
steel		 Nickel base alloys Aluminum
Pure Argon ✔ ✔ ✔ ✔ ✔ X ✔
Pure Helium X X X X X ✔ ✔
Argon-Helium mix X ✔ ✔ ✔ ✔ ✔ ✔
Argon with hydrogen 2- 5% X ✔ X X X ✔ X
Argon with Nitrogen 1-2% X X ✔ ✔ X X X
Argon with helium (30%) & 1-2% Nitrogen X X ✔ ✔ X X X
Welding Shielding gases Chart

 

What is the best gas for TIG Welding?

The Best TIG Welding Gas is Argon (Ar). Argon welding gas can be used for TIG welding of Carbon Steel, Stainless Steel, Aluminum, Copper alloys, or any other material. Argon welding gas provides low ionization and thus gives low heat input.

The welds made with Argon gas shielding are of high quality and very clean surface finish. Argon is having a higher density than Helium and hence requires a low gas flow rate compared to helium.

TIG Welding Gas for Carbon Steel & low alloy steel

Argon is the primary welding gas for TIG Welding of Carbon Steel or low alloy steel. Details about various welding gases used in TIG Welding are given in the chart above for different materials. The TIG welding gas classification for Carbon Steel welding is SG-A as per AWS A5.32 specification.

Nitrogen gas as a welding gas is never used for welding Carbon Steel, low alloy steel, or ferritic stainless steel. The reason is- Nitrogen is responsible for welding porosity in carbon steel, mild steel, low alloy steel & ferritic steel. The shielding gases must not also be mixed with nitrogen for these materials’ welding.

What Gas is Used For TIG Welding Aluminum?

TIG Welding of Aluminum is carried out using pure argon (SG-A) or Argon + Helium mixture (SG-AHe-10). But mostly pure argon is used for TIG welding of Aluminum material.

What Shielding Gas for MIG Welding?

Argon, CO2, Argon-Helium mix, Argon-CO2 mixture are mainly used for MIG Welding gases. Click the below links to learn about various shielding gases used for MIG-MAG & FCAW Welding.

Shielding gases for MIG-MAG, TIG, and FCAW welding and shielding gases purity

Tri-Mix Welding Gas for Stainless Steel Welding

Tri-Mix or Ternary Welding Gas Mixtures are types of welding shielding gases based on three gas components. They provide additional welding arc characteristics to support metal transfer modes such as short circuit, spray or globular for example.

For carbon steel welding SG-ACO-5 (Argon balance, 5- 10% CO2, & 1- 6% oxygen) classification is mainly used in Tri-mix welding gas. SG-AHeO Tri-mix is used for welding stainless steel. SG-AHeO contains Argon, helium, and oxygen welding gases. Helium provides high welding heat and oxygen additions give weld fluidity to eliminate sluggish weld beads.

The mode of metal transfer is usually spray transfer with SG-AHeO (Argon, helium, and oxygen) gas mix. These gas mixtures also reduce weld porosity. SG-AHeO can also be used for welding carbon steel and low steel welding but oxygen content must be kept low.

MIG Welding Gas 75/25

MIG Welding Gas 75/25 or Argon (75%) +CO2 (25%) gas mixture is mainly used for Welding of Mild Steel, Carbon Steel, and low alloy Steel using MIG-MAG Welding. 75-25 Welding Gas Classification number is SG-AC-25 as per AWS A5.32.

powerwelds Welding Tips  
Read More