PrimeWeld TIG225X

Location

Denhac

Lanthanated and pure tungsten available in 3/32. Lanthanted also available in 1/16. Mild steel and aluminum filler wire available in 3/32 and 1/16.
Multiple sizes of gas cup.
Foot pedal for TIG operation
Stick electrodes and clamp available.
Use only 100% argon gas.

Apply PPE.
Plug in torch and work clamp into appropriate terminals for your operation. Plug in foot pedal for TIG.
For TIG, open the gas cylinder valve slowly and completely until the valve stops at maximum “open.” Ensure at least 100PSI in cylinder.
Power on using the blue switch on the back of the chassis. For TIG, set CFH on flow regulator to (rule of thumb) 2x the cup size # on your torch.
Install sharp and clean tungsten, attach work clamp, knob in the correct settings, go.

1. Introduction to TIG Welding

TIG (Tungsten Inert Gas) welding is a precise welding process used for various metals, including stainless steel, carbon steel, aluminum, and bronze. It uses a non-consumable tungsten electrode to produce the weld.

2. TIG Welding Parts Overview

Tungstens
- Blue “Lanthanated” Tungstens: Standard, all-purpose for carbon steel, stainless steel, and aluminum.
- Red “Thoriated” Tungstens: Suitable for specific applications, less commonly used here.
- Matching Tungsten to Filler Rod and Material: Ensure you select the appropriate tungsten based on the material you’re welding. We primarily use 3/32” and a small amount of 1/16” tungstens.
Cups
- Common sizes are #4, #5, and #6. Smaller numbers mean less airflow, ideal for thin stock and low heat applications.
Collet and Collet Body
- These components match the tungsten diameter and hold it in place during welding.
Back Caps
- Match to the length of the tungsten being used (stubby or full length).
Gas Lenses
- Get matched to the collet body for better gas coverage and a more focused arc.
Filler Rod
- Always match the filler rod material to the base material being welded. The diameter of the filler rod should be equal to or smaller than the tungsten diameter.
Supplies on Hand
- We have 1/16″ rods for steel and stainless steel, 3/32″ rods for aluminum, and some bronze filler rods.

3. Machine Settings

Default Machine Settings
- Mode: TIG (AC for aluminum, DC for steel and stainless steel)
- AC Frequency: 120 Hz (set at 12:00)
- AC Balance: ~50% (set at 12:00)
- Start Current: 60-100 amps depending on material thickness (set at 12:00)
- Amperage Rule of Thumb: 1 amp per thousandth (.001”) of material thickness.
- Upslope/Downslope: Set to 0 (full left)
- End Current: 60-100 amps (12:00)
- 2T or 4T: Default to 2T
- Preflow/Postflow: Set preflow at 9:00 and postflow at 12:00
- Pulse Mode: Typically off for basic welding.
Adjusting Gas Flow: Start around 10 CFM, adjust between 8-15 CFM as needed.

4. Startup Checklist

Power On: Switch the breaker located at the back of the machine.
Gas On: Ensure gas is flowing at the correct rate.
Torch Setup: Connect the torch to the (-) port and the ground clamp to the (+) port.
PPE (Personal Protective Equipment):
- Welding Jacket: Wear a flame-resistant jacket.
- Helmet: Use a helmet with a Shade 10 filter.
- Gloves: Wear thinner TIG gloves for dexterity.
- Clothing: Close-toed shoes and non-synthetic long-sleeved clothing to prevent burns.
- Workspace Safety: Clean the area and remove flammable materials. Never weld galvanized or toxic-coated metals.

5. TIG Welding Procedure

Pre-Weld Preparations:
- Optional: Snip filler rods in half for easier handling. Bend the end to avoid poking hazards.
- Ground Clamp: Attach the ground clamp to the material or the work surface.
- Settings: Adjust machine settings based on the material and desired weld.
- Torch Components: Don’t overtighten torch parts. Snug or “two-finger tight” is sufficient.
- Workspace: Clean any rust or mill scale from the workpiece using Scotch-Brite pads, wire wheels, or flap discs. Remove oils with solvents like acetone, and store solvent-soaked rags in the designated flammables bin.
Welding Technique:
- Hold the torch at a 15° angle from perpendicular to the workpiece.
- Push the torch in the direction of travel.
- The tungsten should protrude from the cup by an amount equal to the cup diameter.
- Avoid touching the tungsten to the weld puddle; maintain a controlled arc and smooth puddle.
- Add filler rod as needed, but avoid touching it to the tungsten. Techniques vary by weld type, such as continuous filler or intermittent “dots.”
- Use the post-flow feature to protect the weld until the gas flow stops.
Sharpening Tungsten:
- When to Sharpen: If the point is lost or the tip becomes discolored.
- How to Sharpen: Use the tungsten grinder, matching the tungsten size to the correct hole. Sharpen it to a uniform pointed cone.
- Handling Short Tungsten: Switch to a stubby back cap if the tungsten is too short to be secured.

6. Shutdown Checklist

7. Key Differences in TIG Welding

Brighter Arc: Requires a darker (#10) shade lens in the helmet compared to MIG.
Increased Dexterity: TIG requires precise hand-eye coordination, so thinner gloves are recommended.
Foot Pedal Operation:
- The foot pedal controls both gas and amperage. Gas begins flowing with pre-flow before the current starts, and continues after the pedal is released for post-flow.