20 May

What Makes AC/DC TIG Welding Machines So Great?

When you start TIG welding, the first major setting you have to set up is the current. Using AC or DC has a hugh impact on your weld results. In this article I will give you a best practice guideline that should help you make the right choice for your welding tasks in the future.

TIG welding can be done with both, alternating current (AC) or direct current (DC). The type of current to choose depends on the workpiece material. Generally, Steel would be welded with DC and Aluminium with AC.Even if you’re relatively new to welding, you probably already know that AC and DC welding are types of arc welding using currents to produce an electric arc between an electrode and the metal to be fused. The process involves using a power supply to generate the arc, using either an alternating current (AC) or a direct current (DC).

Choosing a power source (AC or DC) determines the polarity of the electrical current running through the electrode and impacts the quality and strength of the weld.

Known as ‘straight’ or ‘reverse,’ the two types of current flow are sometimes referred to as ‘electrode negative’ and ‘electrode positive.’ The DC polarity is constant, while the AC polarity flows in one direction for half the time and half in the reverse direction.

Why would someone need an AC/DC TIG welder?

Many welders associate TIG with its use on thin metals only, but the reality is TIG welding has numerous applications for professionals and hobbyists. And AC/DC TIG welders are perfect for all those DIY projects such as automotive repairs and pipework.

An AC/DC welder is a versatile machine, giving extra flexibility to work with a broader range of metals and thicknesses with the option to work with alternating or direct current. The AC/DC TIG welder has features including variable current settings, up/down slope settings, a foot pedal, and several time controls, making it possible to expand the types of welds you can create and the types of metals you can work on.

What is AC TIG welding used for?

Welding aluminum is ideal for alternating current (AC) TIG welding since the alternating current has positive and negative cycles. The positive cycle has a scrubbing effect on the metal surface by removing oxides that adversely impact weld quality. In contrast, the negative cycle allows deeper weld penetration. The two cycles work together to produce high-quality aluminum welds.

Since this oxide layer encompasses aluminum, it is more challenging to weld. The oxide melts at a higher temperature (3200ºF) than the base metal (1200ºF) and needs to be broken up to produce a complete weld. Using AC enables a clear view of the weld pool.

Controlling the amount of heat applied to the weld is yet another potential problem since the conductivity strength of aluminum makes keeping enough heat in the weld pool difficult.

Much heat is required, but it needs to be controlled to prevent the weld pool from “running away” or a burn-through. Many experienced TIG welders use a shorter arc length to confine the heat to a smaller area or a foot pedal to allow them to adjust during the welding process.

What can you weld with an AC TIG welder?

AC welding allows aluminum and magnesium welding and is widely used for seam welding in shipbuilding, aluminum pipe TIG welding, automotive work, shipyards, and aerospace applications.

You can set the current higher with AC than with DC, and AC welding provides faster fills and is better for down-hand heavy plate welds. Another of the primary benefits of AC welding comes when working with magnetized materials, making it possible to use it in machinery repairs.

Do I need an AC/DC TIG welder?

Whether you need an AC/DC TIG welder depends on the type of welding you plan to pursue. If you occasionally see yourself welding steel or thick material, you don’t need more than DC. Considering that about 85% of all welding is completed on direct current, the odds are in your favor that you’ll be covered by it.

Some advantages of DC over AC TIG include a more stable arc, higher welding output, deeper penetration, and lower equipment costs. DC TIG welders are substantially cheaper than AC/DC machines, so that you can save money upfront.

However, even though DC covers most welding, it has drawbacks. The metal may be magnetized in some welding applications, and the arc blow issue appears. Switching to AC welding machines with special electrodes dedicated to AC can help you get around the problem.

Also, welding aluminum is impossible when using a DC-only TIG welder. Because of aluminum’s properties, dirt and high heat can wreak havoc when trying to weld it. Here, you’ll discover the AC welder’s main benefit when efficiently performing aluminum TIG welding without worrying about contamination or burning through the material.

What makes AC TIG so beneficial for welding aluminum?

Welding soft and non-ferrous metals require a reliable AC TIG process. As you know, the alternating current flow moves from positive to negative and back again many times each second. Whenever the flow reverses to the positive electrode portion of the AC cycle, meaning the current flows from the base metal back to the electrode, it provides a “cleaning” action as the electric arc blasts away surface oxides.

When the alternating current flows to the negative polarity, from the electrode to the base metal, it enables the metals to fuse correctly without worrying about burn-through or defects. As a result, AC TIG welding is ideal for joining metals such as aluminum, magnesium, and other non-ferrous metals.

Can you weld steel with an AC TIG welder?

Beginning welders have likely heard that everyone uses DC to weld steel and AC for aluminum, concluding that welding steel with AC is impossible. Although it might not be the ideal method, you can TIG weld steel if AC power is all that’s available,

So, even though you can use AC and DC for TIG welding steel, AC is not your better choice. If you’re buying a new machine for welding steel, get one that uses DC, which is more efficient for welding steel. And if you plan on welding steel and aluminum, spend the extra money for an AC/DC TIG welder and cover yourself for both types of material.

The TIG-300PL AC/DC TIG Welder has the versatility you need

PowerWelds is the leader among welding companies and manufacturers for their lineup of affordable welding machines used at home or in the shop. For example, the TIG-300PL AC/DC TIG Welder with Pulse is one of their most versatile welders, ready to meet the challenge of your next project, whether it’s an aluminum sculpture, lightweight bicycle frame, or steel water tank.

The TIG-300PL TIG welding machine has an AC Balance feature that lets you set the length of time to spend on each side of the AC cycle, as it removes oxidation from the part’s surface and impurities from the weld puddle. By varying the signal to a negative or positive time, you can change the degree of “stir” in the weld puddle.

On the other hand, DC TIG provides the low-temperature control for sheet metal or car bodies or the amps you need for thicker material up to 1/2-inch steel. And no welding process can equal the beauty of exposed TIG welds.
Add to those advantages a stick welding mode that saves money on shielding gas when the finesse of TIG welding isn’t required. Merely flip a switch, and you can do all types of repairs around your house or farm with DC stick welding up to 300 amps.

You name it, and the TIG-300PL will make short work of it. Like every PowerWelds product, this machine stands under the harshest and most rugged real-world conditions. And the best part is the TIG-300PL AC/DC welder with Pulse gives you more for your money than other welders in its price range.

powerwelds New Arrivals

20 May

Guide for TIG Welding: 10 Common in TIG Welding Problems, Do You Understand?

Learn about common mistakes when TIG welding and basic tips on how to avoid them. In this article provides a comprehensive look at typical issues encountered in TIG (Tungsten Inert Gas) welding and offers solutions to these problems. The guide includes visual examples to help users identify and correct common issues such as contamination, poor gas coverage, and incorrect settings. It is designed to assist both novice and experienced welders in improving their welding technique and achieving better results.

1. Poor color on stainless

Figure P1A shows discoloration on a stainless steel weld caused by overheating, which not only affects a material’s color but degrades its corrosion resistance and mechanical properties as well. Unfortunately, once this error is made, there is nothing that can be done to fix it. To prevent overheating, reduce amperage, slightly increase travel speed or shorten the arc length. If your welding equipment features pulsed welding capabilities, now is the time to learn how to use them. Pulsing reduces heat input, and it offers excellent control of the weld puddle. Figure P1B shows proper coloration of the stainless.

Figure P1A:Poor color on stainless steel

Figure P1B:Good color on stainless steel

2. Too much amperage on aluminum

Figure P2A shows what a weld bead looks like on aluminum with the amperage set too high. This creates a wider profile, an ill-defined bead and can potentially lead to burn-through. To solve this problem, reduce amperage and/or increase travel speed. Reference back to Figure 2B to identify an ideal weld.

Figure P2A: Excessive amperage heat input

3. Proper arc length control

The color change in the middle of this aluminum weld bead (Figure P3A) resulted from an increase in arc length. Arc length, which is the distance between the electrode and the base metal, determines TIG welding voltage. Holding too long of an arc increases overall heat input and the potential for distortion. It also widens the weld bead while decreasing penetration, and affects weld bead appearance. Practice holding a consistent arc length to improve heat input control and improve weld bead quality.

Figure P3A: Proper arc length control

4. Sugaring on stainless steel

Figure 8 shows sugaring on the backside of a stainless steel weld, a common TIG welding problem. Sugaring (oxidation) occurs around the weld when it is exposed to oxygen in the air. The best way to prevent sugaring is to back purge the weld with argon shielding gas or reduce welding amperage.

Figure P4A: Sugaring on stainless steel

5. Welding aluminum in the wrong polarity/adjusting balance

This TIG weld (Figure P5A) was created with the machine’s polarity set on direct current electrode negative (DCEN). As you can see, the weld did not break down the aluminum oxide layer. The filler metal mixed in with the partially melted oxide, creating the contaminated bead seen here. To defeat this, always TIG weld aluminum with the polarity set to alternating current (AC).

TIG welding in AC (Figure P5B) allows the electrode positive (EP) portion of the cycle to blast away the aluminum oxide while the electrode negative (EN) portion melts the base metal. A feature called AC balance control allows operators to tailor the EP to EN ratio. If you notice a brownish oxidation or flakes that look like black pepper in your weld puddle (Figure P5C), decrease the balance setting. This will increase the time in EP or the time spent in the “cleaning action.” However, note that too much EP causes the tungsten to ball excessively (Figure P5D) and could provide too much etching. Lastly, when TIG welding aluminum, do not start welding until the puddle has the appearance of a shiny dot. This indicates that the oxide has been removed and it is safe to add filler and move forward. Adding filler to the weld zone before removing the oxide layer results in contamination.

Figure P5A :Aluminum welded in DC with argon	Figure P5B: Ideal aluminum weld
Figure P5C: Sugaring on stainless steel	Figure P5D: balled tungsten caused by a low balance setting (excess EP)

6.Weld graininess

Figure P6A: Grainy aluminum weld

Figure 2B shows the way an aluminum TIG bead should look. Figure P6A shows a bead with a grainy appearance, which is typically due to filler metal problems. For instance, a 4043 aluminum filler rod from one manufacturer may have different properties than a 4043 rod from another manufacturer. The welder (if the application permits) may need to adjust filler brand accordingly. The rod may also be defective (too much of a certain ingredient). The welder may even have the wrong type of filler rod, such as 4043 filler instead of 5356 filler.

Prior to welding, always check the filler metal type and remove all grease, oil and moisture from the surface to prevent contamination.

7. Lack of fusion in the root

Figure P7A:Lack of fusion in the root

A number of factors cause lack of fusion at the root of a T-joint or a fillet weld. These include improper fit-up, holding the torch too far away from the joint (increasing arc length) and improperly feeding the filler rod. This issue arises more often with a transformer-based machine — the arc tends to wander between the two sides of the joint as it seeks the path of least resistance. In this case, reducing arc length will provide better directional control and help increase penetration. It is also important not to under-fill the joint or weld too quickly to avoid this TIG welding problem.

Note that inverter-based machines with advanced output controls such as adjustable frequency and pulsing controls offer more control over the arc. These controls create a narrower, more focused arc cone, providing better directional control over the weld puddle and deeper penetration (and often at increased travel speeds).

8. Craters

Craters, such as the one shown in Figure P8A, typically occur at the end of the weld, and they often lead to cracking. Causes include instantly reducing the welding power (which causes the puddle to cool too quickly) and removing the filler rod too quickly at the end of the weld. You can fix crater cracking issues by continuing to feed filler rod while slowly reducing current at the end of a weld. Some TIG welders feature a crater control function that automatically reduces the current at the end of a weld. The result is a good-looking weld bead, as seen in Figure P8B.

Figure P8A： Poorly filled weld craters

Figure P8B： Weld crater filled

9. Dirty base and/or filler metal

One of the first things you should have learned about welding is to clean materials prior to welding. This photo (Figure P9A) shows what happens when you don’t clean the mill scale off hot-rolled mild steel. Clean all base and filler metals, including mill scale, oxide on aluminum, or dirt and grease on filler metals. Grind, brush and wipe away all potential contaminants. For cleaning aluminum, dedicate a stainless steel brush to the task to prevent contamination from other metals.

Figure P9B shows what happens when a weld on mild steel has been properly cleaned before welding. Figure P9C shows a weld made on uncleaned chrome-moly tubing, while Figure P9D shows a weld made on clean material.

Figure P9A: Uncleaned steel weld	Figure P9B: Clean steel weld
Figure P9C:Uncleaned Chrome Moly	Figure P9D :Cleaned chrome moly

10. Poor gas coverage

The weld here shows contamination caused by lack of shielding gas. This can happen when the shielding gas is not turned on, there is either too little or too much gas shielding, or the gas is blown away.

Figure P10A: Poor gas coverage leads to contamination

To troubleshoot gas contamination issues, check the gas cylinder label to ensure you’re using the right type of gas for TIG welding. The most common is 100% argon (or perhaps an argon/helium blend for thick aluminum). Attempting to weld with an argon/carbon dioxide mix (commonly used for MIG welding) will cause immediate contamination.
Set the proper gas flow rate, which should be 15 to 20 cubic feet per hour (cfh) for most applications. Welders commonly — and incorrectly — assume that a higher gas flow/pressure provides greater protection. In fact, excessive gas flow creates turbulence and swirling currents that pull in unwanted airborne contaminants. It can also cause arc wandering). Generally, err on the lower side of recommended shielding gas rates to ensure proper shielding coverage without turbulence.
Check all the fittings and hoses for leaks. Any breach may pull air into the shielding gas stream, which can contaminate the cause the weld. Rub soapy water over the hose and all fittings. If bubbles form, you have a leak and need to replace the defective components.
Assuming you have a full cylinder, the right gas and no leaks, you may have a tank contaminated with moisture. Shielding gas cylinder contamination does not happen frequently, but it is possible. Check with your gas supplier to resolve this issue.

This article originally appeared in The Fabricator Magazine.

powerwelds Welding Tips

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:

Automotive Industry: TIG welding is used to assemble exhaust systems, fuel tanks, and engine components.
Aerospace Industry: It is employed on aircraft components like engine parts, aluminum and titanium structural members, and fuel lines.
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:

Gather the necessary equipment: TIG welding machine, tungsten electrode, filler rod, gas cylinder, protective clothing, and welding helmet.
Prepare the workpiece by cleaning it thoroughly with a wire brush or solvent to ensure a clean surface.
Set up the TIG welding machine and adjust the settings to match the material and thickness.
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.
Maintain a steady hand and move the torch in a controlled manner, directing the arc along your desired weld path.
Control the heat input by adjusting the amperage and filler rod as needed.
Keep the torch close to the workpiece for better control and visibility.
Once the weld is complete, gradually reduce the amperage and allow the weld to cool.
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:

Power Source: Provides electrical energy for the welding process.
TIG Torch: Holds the tungsten electrode and controls the shielding gas flow.
Tungsten Electrode: Forms the arc and withstands high temperatures.
Shielding Gas: Protects the weld area from atmospheric contamination.
Filler Metal: Optional material added to reinforce the weld.
Gas Cylinder: Stores the shielding gas, such as argon or helium.
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:

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

What Are the Disadvantages of TIG Welding?

Disadvantages of TIG welding include:

Compared to other welding techniques like MIG, TIG welding generally takes longer.
TIG welding requires a higher level of skill and expertise to operate the equipment effectively.
It may be challenging to weld thick materials because of the TIG process’ slow deposition rate.
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:

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.
Speed: Laser welding is typically faster than TIG welding.
Precision: With a smaller heat-affected zone and greater precision, laser welding produces more compact welds.
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

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

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

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

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

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

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

30 April

Super Practical TIG Welding Guide and Tips

TIG welding, known for its precision and cleanliness, utilizes a tungsten electrode to produce the weld. This method is highly favored for its ability to weld a wide variety of metals without generating spatter or significant smoke. Today, we’re delving deep into the intricacies of TIG (Tungsten Inert Gas) welding, exploring its advantages, techniques, and some hands-on tips that can significantly enhance your welding skills. The welding machine used in this teaching session is the PowerWelds TIG-200PI AC DC TIG welding machine.

Features and Functionality

The TIG-200PI AC DC TIG welding machineoperates on both AC (Alternating Current) and DC (Direct Current), making it suitable for welding not only steel and stainless steel but also aluminum. The inclusion of square wave inverter technology is a significant upgrade, allowing for precise control over the AC balance and improving the quality of welds on aluminum.

One of the remarkable aspects of the TIG-200PI AC DC TIG welding machine is its user-friendly interface. It includes intuitive controls for adjusting parameters such as amperage, AC balance, and pulse frequency, which are crucial for managing the heat input and weld bead characteristics. This makes it ideal for both beginners and seasoned professionals looking to refine their technique.

Practical Welding Lessons and Tips

In our comprehensive guide to mastering TIG welding with the TIG-200PI AC DC TIG welding machine, we delve deeper into practical lessons and tips that will help both novices and experienced welders refine their skills. Here’s an expanded look at the hands-on experiences, techniques, and nuances of TIG welding that we explored during our session.

Getting Started with Steel

For those new to TIG welding, starting with steel is advisable. Steel is forgiving and a great material to practice achieving consistent bead appearance and heat control. During our session, we practiced adjusting the amperage and experimented with the foot pedal, which allows for real-time control of the heat input during the welding process. Beginners should focus on maintaining a steady hand and consistent travel speed to ensure even welds.

Exploring Aluminum Welding

Aluminum welding with the TIG-200PI AC DC TIG welding machine is facilitated by its AC capability, which is crucial for cleaning the oxidized layer on aluminum before the weld puddle is formed. We adjusted the AC balance to control the cleaning effect versus the penetration, finding a sweet spot that allows for clean, strong welds. For aluminum, the use of a higher frequency setting helps stabilize the arc and refine the bead profile.

Pulse Welding Techniques

Pulse welding is a standout feature of the TIG-200PI AC DC TIG welding machine, allowing for better control over heat input, which is especially beneficial when working with thinner materials or when precision is paramount. By setting the machine to pulse, the welder alternates between a high peak current and a low background current. This technique reduces overall heat input, minimizes warping, and can improve the appearance of the weld. During our test, we adjusted the pulse frequency and observed how different settings affected the weld pool dynamics and bead characteristics.

Advanced Controls and Settings

The TIG-200PI AC DC TIG welding machine offers a range of settings that can be fine-tuned for specific welding needs. We explored the AC balance for aluminum, adjusting how much time the current spends in each phase of the cycle to manage cleaning action and penetration depth. We also experimented with the post flow control, which governs how long the gas continues to flow after the arc stops, protecting the weld as it cools.

Real-World Applications and Problem Solving

In a practical scenario, we simulated a repair task on a thin metal sheet, a common challenge in automotive repairs. By adjusting the welder to a lower amperage and using a triangular wave for a sharper, less penetrating arc, we were able to make precise welds without burning through the metal. This setting is particularly useful for automotive enthusiasts looking to repair body panels or create custom parts.

Tips for Continuous Improvement

1.Practice Consistency: The key to mastering TIG welding is consistency in your technique. Regular practice on scrap materials will help develop muscle memory for torch and pedal control.

2.Material Preparation: Always ensure your material is clean and properly prepped before welding. This is especially important for materials like aluminum, which oxidize quickly and can contaminate the weld.

3.Watch and Learn: Observing the behavior of the weld pool and learning to adjust your technique in real-time based on what you see is crucial for advancing your skills.

We also explored the pulse welding feature, which is invaluable for reducing heat input while improving the aesthetics of the weld bead. Pulse welding is particularly useful when working with thin materials or intricate parts, as it helps prevent warping and burn-through.

Safety and Maintenance

Welding, while rewarding, poses its own set of risks. It’s imperative to use the provided protective gear and to ensure that the welding environment is safe and well-ventilated. Regular maintenance of the welder is also crucial to ensure its longevity and performance. The TIG-200PI AC DC TIG welding machine’s design facilitates easy access to consumables and parts that might need regular replacement, like the tungsten electrode and shielding gas nozzles.

Conclusion

The TIG-200PI AC DC TIG welding machine represents a significant advancement in TIG welding technology, offering portability, power, and precision in a compact package. Whether you’re a hobbyist looking to craft perfect welds on a motorcycle frame or a professional tackling a complex fabrication project, the TIG-200PI AC DC TIG welding machine offers the capabilities and comfort needed to achieve high-quality results. For those eager to enhance their TIG welding skills, investing in a machine like the TIG-200PI AC DC TIG welding machine and spending time practicing different techniques and settings is key. Remember, like any craft, TIG welding requires patience and practice to master.

powerwelds New Arrivals

22 April

How to Compare and Choose Between MIG Welding and TIG Welding?

There are many best methods to fuse metals by welding through various methods. Among many options are MIG and TIG — MIG stands for Metal Inert Gas and Tungsten Inert Gas. The debate over which method is the best-doing rounds for quite some time now. Each method has its benefits, given the nature of the work/project.

To compare the two, let us help you understand MIG welding and TIG welding. We will additionally look into their differences and ultimately choose which is better.

What is MIG?

Metal Inert Gas welding or MIG welding is the popular and easy welding process. A consumable wire electrode is needed to create an electrical arc between the item being welded and the consumable wire doing the welding. The metal rod is used as an electrode and also as a filling material.

Once the metal heats up and the welding process begins, the welding gun releases inert gas from the gas nozzle to keep the contaminants away. The gas is the combination of CO2 and Argon.

MIG Welding Components –

Power — The source is mainly DC with a steady voltage.
Wire
Electrode
Torch
Conduit
Filler metal
Gas shielding

TIG Welding

Tungsten Inert Gas welding or TIG welding is named because of the tungsten electrode inside the welding. Since the tungsten doesn’t readily melt, it conducts the electricity arc directly to the components you need to fuse. In other words, the wire is held by the operator that is touched to the electrode to melt into the base item.

TIG welding, or Tungsten Inert Gas welding, is very similar to MIG welding. TIG still relies on a wire to feed and heat up to melt the base item and wire to form the weld.

TIG Welding Components –

Power — The source can be AC or DC.
Torch
Foot pedal -This controls the electricity that goes to the torch.
Electrode and gas shielding
Filler material –
Backing bars: These help cool the weld area faster than on its own.

Applications of MIG & TIG Welding

MIG Welding

There are various MIG welding applications, and before that, one has to gauge how a particular welding process fits the project. For instance, when working on thicker metals, the filler used in MIG welding will firmly hold the parts.

MIG welding is versatile and can be used on a wide variety of projects as long as the welder matches the gas and wire to the types of metal he/she needs to conjoin.

Here are some of the examples of MIG applications:

Metal component repairs
Automotive repairs and manufacturing
Trailer hitches
Farming equipment
Construction welding
Pipe welding
Underwater welding projects
Railroad track repair
Shipbuilding

TIG Welding

For a work that requires precision, TIG welding is the top choice. It can be used on various metals (steel, bronze, nickel, brass, copper, gold, etc.), which is why the process is applied in diverse industries, helping create and repair many items.

This welding process is known for its strength and precision.

Here are some of the examples of industries that use TIG welding –

Aircrafts & Spaceships
Automobile
Industrial fixtures
Metal sculptures

Which one is better — MIG or TIG?

Although the process may seem similar, some differences set the processes apart. For instance, MIG uses a consumable wire, whereas TIG uses a tungsten electrode that isn’t consumable.

Now, each welding process has its usage that best fits them; that is where the difference lies. If you want speed over accuracy, MIG is for you, and if you choose the latter, TIG can give you the best results. TIG welding is more suitable for thinner metals, and MIG welds work well with extensive projects with thick metals.

Your better understanding of the MIG and TIG welding process will help you make an informed choice when working on the project.

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