TIG Welding – Beginners Guide

We are always interested in our customer’s welding product needs. To maintain it’s growth pattern PWS has developed a variety of products and many of the products we offer are of a “value added” nature. PWS is able to assist customers in improving their production processes through equipment to enhance or improve welding quality.

These activities serve to broaden the product and services offering and make the company less dependent on outside sources for development. The acceptance of new equipment has been researched and appears to be welcomed consideration to the current customer base. Continual product development will ensure balanced growth and recognition as a source of expertise in welding equipment and processes.


SERVICES INCLUDE:
 Design services for precision welding systems (manual load/unload or semi-automatic)
 Integration of welding system accessories & site installation assistance
 Experienced staff for custom design & manufacture of tooling, fixtures & specialty torch nozzles
 Free weld application review & process recommendation

TECHNICAL SUPPORT:
 Troubleshooting, maintenance & repair of equipment
 Weld training – skills development
 Weld development – material evaluation, joint design, weld parameter development
 Comprehensive consumable inventory stock of replacement parts for plasma power supplies, accessories & plasma welding torches

CUSTOM PRODUCTS AND ACCESSORIES:
Special gas shields – MIG, TIG & Plasma
Torch slides – X, Y, Z


TIG Welding – Beginners Guide

TIG welding is probably he most complicated type of welding there is, and for a beginner the shear number of variable can be a bit confusing. Below is a break down on all the different areas with some “numbers” to help you get started.

TIG Welding – Beginners Guide – Gas

Now you may think talking about gas before the welder is odd, but bear in mind that if you are on a budget then the gas is going to represent a significant outlay.

Unlike MIG welding TIG welding can only use pure argon (or other specialist gases), so using food grade CO2 for example is not possible.

TIG Welding – Beginners Guide – Welders

Make sure that the welder actually comes with a proper TIG torch, as some Arc Welders can be used for TIG welding but do not come supplied with a TIG torch as pictured below.

A TIG Torch

TIG Welding – Beginners Guide – The Tungsten

The tungsten is the electrode that sticks out of the front of the torch. Confusingly there are various different types, that are better suited to different applications. Your welder may come supplied (as mine did) with an unsuitable tungsten electrode. Most people suggest a 2% thoriated tungsten, but this is radioactive, so perhaps go for a 1-2% lanthanated electrode which I believe performs similarly

You should sharpen your tungsten before first use. 

OK so hopefully that covers the gear now a little on technique.

TIG Welding – Beginners Guide – Holding the Tig Torch  

To avoid damaging the electrode, you will need to hold it around 2 – 3mm from the working surface. With a welding mask on this is no mean feat, and will take a great deal of practice to get the hang of. The torch should be held in a way that is very comfortable;

Index Finger on Top
Or like a pencil

Gloves should be used or you will get sun burn from the UV radiation emitted from the arc. If you are working on a large item, it may heat up meaning you will need something heat proof to rest your hand on.

The torch should be held with the electrode as upright as  possible, whilst still allowing you to see what you are doing.

TIG Welding – Beginners Guide – Setting the Amperage

On the most basic of TIG welders there will be an amperage control, too little amperage and you will not melt the metal, too much and you make a hole.

It is recommended around 65 amps for 16 gauge steel  (1.63mm). So a bit more for thicker stuff, and a bit less for thinner stuff, remember that the maximum amperage you can use will be limited by the diameter of the tungsten you are using. 1.6mm tungsten will go up to around 90 amps, if you intend to use more amps then get a thicker electrode.

The better the conductivity of the metal the higher your amperage will have to be, aluminum requires a higher amperage that steel for the same thickness.

TIG Welding – Beginners Guide -Gas Flow Rate

During welding set gas flow around 7 – 8 liters per minute.


PROCESS WELDING SYSTEMS AUTOMATED WELDING SYSTEMS TAKE YOU TO THE NEXT LEVEL:

Our automated system helps  you increase welding quality, improve welding productivity, enhance the working environment and decrease manufacturing cost.

Special Purpose Machines (SPM) with simple timer and contractor control to complex designs using CNC controllers, servo motors, pneumatics, hydraulics as requirement.

Process Welding Systems’ design, manufacture and sell complete weld automation stations for mass production with automated welding of various components , equipments, overlay metal build up, hard-facing and metal spray applications .

See our CUSTOM AUTOMATED LATHE

Let Us Know More About You

We are always interested in our customer’s welding product needs. To maintain it’s growth pattern PWS has developed a variety of products and many of the products we offer are of a “value added” nature. PWS is able to assist customers in improving their production processes through equipment to enhance or improve welding quality.

These activities serve to broaden the product and services offering and make the company less dependent on outside sources for development. The acceptance of new equipment has been researched and appears to be welcomed consideration to the current customer base. Continual product development will ensure balanced growth and recognition as a source of expertise in welding equipment and processes.


SERVICES INCLUDE:
 Design services for precision welding systems (manual load/unload or semi-automatic)
 Integration of welding system accessories & site installation assistance
 Experienced staff for custom design & manufacture of tooling, fixtures & specialty torch nozzles
 Free weld application review & process recommendation

TECHNICAL SUPPORT:
 Troubleshooting, maintenance & repair of equipment
 Weld training – skills development
 Weld development – material evaluation, joint design, weld parameter development
 Comprehensive consumable inventory stock of replacement parts for plasma power supplies, accessories & plasma welding torches

CUSTOM PRODUCTS AND ACCESSORIES:
Special gas shields – MIG, TIG & Plasma
 Torch slides – X, Y, Z
 Special plasma nozzles – custom sizes
 Contract welding
 Tungsten electrode grinders

Let Us Help You Implement a Production System That Will Compete With the Growing Overseas Market

Where We Stand Now

With international competition on the rise, how do you keep your customers coming back? In countries like China and India manufacturing exports continue to grow. These countries have implemented a new policy which emphasizes the development of domestic innovative capability.

This has led to increased spending on R&D and a growing researcher base. Soon, not only will the part be available at a lower cost but at comparable quality as well. If developed countries are to
remain competitive in the global economy, they will have to rely more on technology. Investment in technology is therefore a crucial factor for  sustained economic health. A continuous process of change, innovation and productivity will allow you to be competitive as the global market continues to evolve. Innovate, or lose.


Whoever makes things better, cheaper, faster wins! America must continue to bethe leader.


Staying Competitive

In order to compete with countries like China and India we need to adopt equipment and technology that will lower production cost while enhancing the product quality at the same time. Companies must now look for new and innovative ways to improve their processes, their workers productivity and, ultimately, their overall equipment effectiveness.

Let PWS Help

With quality and productivity as buzzwords, and customers demanding superior products, implementing an automated welding system may determine whether a company remains competitive. Automating your welding production offer three main advantages: decreased variable labor costs, improved weld quality and decreased scrap.

Benefits of Automated Welding

Decreased Variable Labor Costs: A machine controlled system always repeats the same welding parameters. Reliance on human welders dramatically increases a manufacturer’s labor costs. A fully automatic system with sufficient stations can run at four or at eight times the pace of a skilled welder.

Improved Weld Quality: Mechanized welding improves weld integrity and repeatability. Humans tend to “smooth over” a mistake with the torch, hiding lack of penetration or a possible flawed weld.

Decreased Scrap/Rework: It’s never good to throw away parts with accumulated significant value because of a welders lack of detail. Automating weld parameters and part placement decreased the error potential.


A fully automatic system with sufficient stations can run at four or at eight times the pace of a skilled welder.


Some of Our Customers

  • General Atomics
  • Teledyne Energy
  • McKenna Machine
  • Delphi Automotive
  • Fuel Cell Energy Corp.
  • Angio-Dynamics
  • Pratt & Whitney
  • Parker Hannifin Corp.
  • Lake Region
  • Draper Laboratory

Low AMP Plasma Welding Check List for Contaminated Electrode, Dirty Weld Nozzles and Plasma Torch Care.

Where We Stand Now

  1. A dark blue or black tungsten (Figure B) is a sign of moisture or oxygen getting into the plasma gas line (also called the pilot gas line). If the gas is good quality and the gas lines are leak free the tungsten should remain a gray color (Figure A) not dark blue or black. Moisture and oxygen in the gas lines deteriorate the tungsten electrode and thus the number of arc starts that the tungsten electrode can produce is reduced. This cuts down on the number of arc starts in production and decreases production.
  2. Any leaks in the gas lines or fittings can allow air to be sucked into the gas system which adds oxygen and moisture to the welding gases being used. Levels of oxygen and water should be less than 5ppm. The most important gas in plasma welding is the pilot gas, also called plasma gas, is always argon gas. The grade of argon being used should be at least 99.998% pure argon. In plasma welding if the gas is not pure it will contaminate the tungsten electrode and turn the tungsten electrode a dark blue and black color. If the problem is very severe the discoloration will run all the way to the point of the tungsten electrode and the nozzles on the torch will clog up.

  3. To check for gas leaks one needs to install a bottle of gas on the pilot gas line and it is recommended that the gas bottle is used with a dual stage regulator with a stainless steel diaphragm. Next take a nozzle for the torch and solder the orifice of the nozzle closed. Clean the nozzle after soldering with acetone or alcohol and install a small o’ring that will make a seal when the nozzle is screwed into the torch and hand tightened Also make sure that where the nozzle seats against the torch body is clean and free of dirt. If the nozzle does not seat well against the torch body a gas leak can occur. Turn the pilot gas flowmeter up to its highest flow and turn off the argon gas bottle. This will trap gas in between the tip of the torch nozzle and the argon gas bottle. Take a reading on the high pressure gas gauge of the gas regulator. Wait 15 to 30 minutes. If the gas system is leak free the gauge reading will stay the same as when the gas bottle was turned off. If the gauge pressure drops then there is a gas leak in the system. The leak could be caused by a hole in the gas hoses or defective fittings and gaskets.

  4. If the system has a leak you must then go through and check fittings to make sure they are tight and make sure that gaskets are sealing. You can also pinch the plastic hose where the torch connects and trap gas from where the hose is pinched back to the regulator and see if still leaks thus working your back through the gas system.

  5. Check for cracks in the torch body. If the torch has a back cap check the o’ring on the cap and check the cap for holes or cracks.

  6. After it has been determined that the gas system is leak free the system needs to be purged. By purging the gas lines it will clean all of the moisture and oxygen out of the lines so that you will only have good clean gas in the system. Turn the pilot gas flow up to its highest flow rate and let the gas run through the lines for at least 30 minutes to and hour. Next start a pilot arc and let it run at normal pilot arc gas settings (0.4 to 0.6 liters per minute) for 10 minutes. Turn off the pilot arc and check to see if the color of the tungsten electrode is gray. If it is gray your gas system is clean. If the color is black and blue then the system needs to purge longer to make sure it is clean.

  7. If your welding system is shut down over night air with oxygen and moisture will get up inside the plasma torch. Before starting to weld on the next day you need to again purge the gas lines approximately 5 to 10 minutes before starting to weld. You may want to turn the pilot gas down to a very low flow such as 0.1 liters per minute and let the gas run all night to keep the gas line clean. It will be such a low flow that it will not be of any economic importance.

  8. When the pilot arc is turned off let the gas continue to flow for at least 10 to 15 seconds before turning off main power. The gas flow will keep the tungsten electrode from oxidizing until it cools down.

  9. Whenever thinking about electrode life, electrode contamination, ease of arc starting and arc stability you should not forget that the exchange of ions takes place within the plasma column in both directions which is from the electrode to the work piece and from the work piece to the electrode. If impurities such as lead, sulfur, aluminum, magnesium, copper, zinc, brass, oil, grease or any other dirty elements are on or in the material being welded they will contaminate the tungsten electrode and nozzle. You then cannot count on a maximum number of welds before replacing the tungsten electrode and weld nozzle.

  10. Clean the nozzle orifice with acetone or alcohol and a Q-tip. A round wooden toothpick can be used to clean the orifice of the nozzle. Weld nozzles trap contamination during welding and will need to be cleaned every time the tungsten is re-ground.

  11. The pilot arc should be bright white with a light blue tint color. If the color changes to orange or purple that is a sign of contamination. Also the pilot arc will draw back into the nozzle, which is a sign that the tungsten electrode has deteriorated.

  12. WARNING: It is extremely important that when tightening the nozzle onto the torch head that you do not over tighten the nozzle and strip the threads. Copper is a very soft material, which makes it easier to over tighten the nozzle. Tighten the nozzle until it barely makes intimate contact with the end of the torch head. It is recommended that pliers be used to tighten the nozzle but be careful not to grab the torch head with the pliers. Also be careful not to cross thread the nozzle. If the nozzle is cross threaded it will damage the threads inside the torch head. Do not get dirt, grease or oil inside the torch head or on the nozzle threads, which will damage the threads in the torch head. If the torch head is damaged by the pliers it can cause a gas leak between the nozzle and torch head and the nozzle will not seat properly against the water cooled part of the torch head. If the threads are stripped and the torch head is damaged the torch will have to be replaced. Periodically clean the inside of the torch and thread where the nozzle seat with alcohol of acetone. Make sure that the technician that handle the torch and installs nozzles hands are clean. Dirt, oil, grease and grit is not acceptable on any of the torch parts. The plasma welding torch is an expensive device and should handled with great care.

  13. The type of hose material that the pilot gas and shield gas are passed through is very important. All plastics can have moisture and oxygen that diffused through the walls of the hose material. When welding sensitive materials such as titanium the welding system may need to plumbed with stainless steel gas lines.