How To TIG Weld

[Ji Gantor]

"Pulse Freq"

The pulse frequency dial allows us to adjust the penetration of our weld. It also can adjust the width of the puddle if played with.

Ji

[Ji Gantor]

"Post Gas"

The post gas dial is set so the argon gas will continue to flow out protecting the job after we have released the trigger. After all the molten aluminium takes a few seconds to harden. So we set the time interval accordingly. When you have finished a run and have released the trigger keep the gun in place until the gas has stopped flowing or until the puddle has hardened.

Ji

[Ji Gantor]

"Clear Width"

The clear width dial allows us to adjust the high frequency cleaning width required for aluminium welding. This cleaning process can be seen as a white boarder around our weld.

Ji

[Ji Gantor]

Next are the switches.
These switches convert the welder from AC to DC and a few other things so lets take look.

Ji

[Ji Gantor]

The first toggle switch if pointing up allows us to vary the amperage via a foot control.
If pointing down the current will be set by its duty cycle between the base and peak current dial settings.

Ji

[Ji Gantor]

The middle toggle switch is self explanatory.
If pointing up the unit will be set to AC for aluminium and thus the earth clamp must be connected to the positive feed.
If pointing down the unit is set to work in DC and the earth clamp is connected to the negative feed.

Ji

[Ji Gantor]

The last toggle switch has three positions.
If pointing up we are ready for TIG welding.
In the middle the unit is able to Manual Arc Weld and
if pointing down my welder is a plasma cutter.

Ji

[Ji Gantor]

The flow of gas required to weld aluminium is some where between 12-15 litres per minute.
This is set via a flow meter attached to the regulator or a portable unit that is pushed on to the nozzel of the gun when the trigger is pulled.

Ji

[Ji Gantor]

If we now go back to the Miller's calculator we find that a 2.4mm diameter electrode is what is required to weld 3mm thick aluminium.
Don't try and use a 1.6mm electrode or it will burn up into the gun as soon as the arc is started.
Also don't sharpen the electrode when welding aluminium, just place it in the collet as is. With in a few seconds of welding you will notice that the end of the electrode will have a cool looking ball attached. This is what we are looking for.
The white colour band electrode is what we need for aluminium.
Extend the electrode about 2-5mm outside the gas cup nozzle.
The gas cup should be 9.5-11mm.

Ji

[Mick22]

Good stuff Ji

I have been looking at buying one of those chinese 4in1 welders for a while but hadn't had a report to hear how good they were. I was also a bit scared off by all the knobs, because I'm new to TIG. This thread has answered all my questiond in one go

[Lozza]

Got a tig ticket in 98. Owned a well used Sincosold 200A AC/DC since 04.
Weld every second day and the in between day I machine something.
X-Rays and Gamma rays from arcs are indeed worse than the sun.
Gas companies will rip you off blind for cylinder rentals. FZ  from Air Liquide is the best value.
Gas Lenses/Diffusers are good gas economy (gas consumption down to 8-10 l/min) and coverage area increased.
TIG parts are normaly cheaper at the local welding shop than ebay.
Multitude of different length collets, different shaped ceramics and collet lock thingys to get into tight places.
Ceriated electrodes are crap and give them a wide berth(supposed to do both AC and DC but do neither any good).
One drawback is you can't usualy weld outside without some sort of a good windbreak, as your gas will just waft away.

[Ji Gantor]

Hi Mick22,
I think most want a bee TIG welders feel the same as you about the Chinese units.
The manuals don't tell you a thing about how to set it up.
I wish I had some one to tell me about all this stuff but as I have found out in life it is better to bight off more than you can chew and chew like mad.

Some of these cheap welders are not worth the money as you spend more time sending them back from where they came.

I hope I and the other dedicated members have helped you and many more like you find a TIG torch in your hand in the future.

Ji

[Ji Gantor]

Hi Lozza,
Thanks for adding to this topic.
Your contribution is gold.
As we have seen a lot of interested TIG welders are enjoying and benefiting from your efforts.

Ji

[Ji Gantor]

The other way to get into TIG welding is to purchase a second hand unit.
These are cheaper than a new one and better quality than a Chinese unit.
Miller, Lincoln ....... all join the list of the top shelf companies.

The attached image is of an old unit that still works great. It has a water cooled handle and a lot less dials. Parts are getting hard to find but not much has gone wrong with this welder because it is a quality product.

Ji

[Ji Gantor]

When you start out buying TIG gear hire a D size gas bottle from the cheapest supplier you can find as Lozza explained.
Don't get fooled into these throw away bottles.
They contain 60 litres of gas which should provide about 6 minutes of welding. Sounds good but the gas regulator and fittings that come with it leak gas every where and they are push fittings not clamped so impossible to seal.
Before you have finished one run you will need another $35.00 bottle.
A cheap solution that ends quite dear.

Ji