10 Things to Consider When Buying aluminium tig welders

Knowing where to start with TIG welding can seem like a daunting process but we’ve made it easy with everything you need to know about choosing a TIG welder.

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What is TIG welding?

TIG welding, which stands for Tungsten Inert Gas welding and is also known as GTAW (Gas Tungsten Arc Welding) is a type of welding that uses a non-consumable tungsten electrode to produce the weld. It differs from MIG welding through how the arc is used, for example MIG welding uses a wire to create the spark needed for welding, whereas TIG welding uses rods of tungsten to weld metals together.

What works for my budget?

Like any piece of equipment, you generally get what you pay for in terms of machine quality and durability, however what you set your budget as also depends on how advanced you need the machine to be. A classic TIG welder like the Lincoln Aspect 200A AC/DC is typically at the more affordable end of AC/DC TIG machines, whereas a multi-process machine such as the ESAB Rebel 205ic AC/DC or Parweld XTM211Di can be more costly thanks to there advanced capabilities.

What materials can be welded?

TIG welders have the benefit of allowing the welding of more metals and alloys than any other process, meaning materials like stainless steel, aluminium, magnesium, copper, brass, bronze and even gold can be welded.

AC/DC vs DC only TIG Machines                                                                     

With AC/DC machines your options are fairly unlimited as you can switch the current type depending on the metal you are working with, while DC only machines are used most commonly for metals like mild steel or stainless steel. If you are welding aluminium then you would need an AC/DC/ TIG welding machine for this. It also worth noting which tungsten’s you may need depending on what material you’re welding. Thoriated (red tungsten) for mild steel and stainless and Zirconiated (white tungsten) for aluminium.

What benefits are there using a higher frequency on AC tig?

Combined with adjusting the balance control to increase the electrode negative polarity—resulting in deeper penetration and tungsten that doesn’t ball up — high AC frequency provides the ability to weld very tight joints with good penetration and without the risk of laying down too much filler metal. 

What is pulse welding?

Pulse welding is welding that alternates between a high and low current. This reduces the overall heat input and spatter while ensuring greater resistance to a lack of fusion. The benefit of pulse welding is that you can weld both thicker and thinner metals without burning through them. 

Are there any benefits of 3 phase over single phase?                              

Comparing single-phase vs three-phase power, three-phase power supplies are more efficient. A three-phase power supply can transmit three times as much power as a single-phase power supply, while only needing one additional wire (that is, three wires instead of two). This allows for more amperage on a machine, meaning thicker materials can be welded or allows for a higher duty cycle meaning longer weld times. 

What is the difference between Lift TIG and HF TIG?                                          

Lift TIG and HF (high-frequency) TIG are two different ways of starting the arc that allows welding between the tungsten rod and the work material to take place. With Lift TIG, the tungsten electrode must be touched to the metal and lifted away a little. When the tungsten touches the metal the current is low so the electrode and workpiece do not stick together. It is only when there is a gap between the two that the machine senses the break and supplies the full current to start welding correctly.

HF TIG however occurs when the welder places the tungsten rod close to the metal and presses the torch trigger to start the arc and begin welding. HF TIG is an option available on most professional TIG machines which allow you to choose between Lift and HG to start the welding process.

Why should I use a TIG pedal with my TIG welder?                                    

Simply put, having a TIG pedal allows you to have more control over the amperage being used and therefore more control over the accuracy and quality of the final weld.

See the range of TIG Foot Pedals at Engweld.

Input voltage & electrical supply – What you need to know

Electricity supplies can vary across the UK so before you begin TIG welding it is important to know where you will be carrying it out. Standard UK mains outlets supply 230v, however you may be limited by a smaller voltage available in your workspace so also check what amp rating you have to calculate the power needed to run your machine and ensure you have enough. To know what supply you will need, you can use the rule of 1 to 10. 1A in the supply means 10A out, therefore a 240A machine would need a 24A input etc.  

IP23 Rating: IP23 vs IP23S

AN IP rating refers to the Ingress Protection rating of a TIG machine which provides information on

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The level of protection it has from foreign particles like dust or water. IP ratings can vary from the machine having no protection to protection from a particular distance or full protection from strong jets of water or even high levels of pressure when submerged. The additional letter given on an IP23S rating refers to how the machine was tested with an S meaning the machine was stationary during the water test. 

Everything to know about warranty

When buying a TIG welder you must ensure that you have the right cover so you are protected if issues occur. A warranty will mean that you get the correct aftercare you need to fix problems and keep your machine in good condition. By purchasing from Engweld and getting our warranty, you will have access to full service & repair facilities at our branches and even the benefit of on-site visits to get it fixed.

Different projects require different methods and tools, in this way, welding different materials requires you to choose the right tools to get your desired results. Working with aluminium is difficult due to its high conductivity and low melting point, while the oxidised film on the aluminium surface has a different melting point to the aluminium itself and is therefore tricky to work with for even experienced welders.

Aluminium is suitable for both MIG and TIG welding, the difference between the most suitable method comes from the thickness of the material, for thicker welding MIG is recommended as it can do the job faster, whereas for thinner aluminium TIG is more suitable. In this article, we will be looking at Aluminium TIG welding.

In most cases, TIG welding is used when working with aluminium. Due to the increased control you have when using this method, you have the ability to prevent the aluminium from overheating.

The selection of a filler rod is a critical aspect of TIG welding, the use of both hands affords the welder excellent control, and by choosing a rod that is more forgiving in terms of the weld parameters you are able to have better control over the weld pool, which results in a cleaner and better-finished weld. As you do not use mechanical feeding for TIG, otherwise known as GTAW welding, you eliminate the feedability issues that are often associated with welding methods that use automated wire feeders.

TIG welding, due to the need to use two hands in order to operate both the welding torch and the filler material simultaneously, forces you to take more time and therefore is a better option where quality and attention to detail are important. As you feed the filler yourself, you also get work that is spatter free, which results in a cleaner finish.

The correct TIG welding machine

TIG welders that are suitable for aluminium typically have the following characteristics:

• AC-powered, the alternative current makes it more suitable for dealing with the oxide film on the aluminium surface.
• The output power range is up to 500A on the larger TIG machines.
• The welding should feature a low amperage, meaning the arc stability must not exceed 10 amperes.
• Its duty cycle should ideally be between 50% – 80%, although this may differ.

For smaller and more precise welds and projects involving aluminium, TIG welding is better suited due to the two-handed operation. This forces the welder to be more methodical and work at a slower pace, which allows greater care to be taken, essential when working with thin aluminium. The method also yields a cleaner and smoother finish as it should be defect-free whilst ensuring a reliable joint is made. However, this more time-consuming approach, coupled with the increased cost of the materials and equipment does make this a more costly approach to aluminium welding.

There are major differences between MIG and TIG welding, especially when working with aluminium. Each approach has its drawbacks and advantages.

TIG welding would be better suited for your aluminium welding work if:

• Your welding needs to be aesthetically pleasing and offer a beautiful finish, this is achieved through identical weld beads.
• Great attention to detail is required.
• Your work must be spatter free, which results in a cleaner finish.
• Your work area is extremely clean.
• The projects are small in nature.
• The weld does not involve cast iron.
• You wish to have more control over your weld.
• Stronger welds are needed.
• Less maintenance is needed, as with MIG welding, there is no sanding or cleaning required between jobs.

The Gases Used

During TIG welding, inert gases are used in order to protect the weld pool from contaminants such as moisture, which have detrimental impacts on the integrity of the weld. Typically, when working with aluminium, Argon gas is used.

As an inert, noble gas, it is colourless, odourless, and most importantly from a welders perspective, it is a non-chemically reactive gas. This means that the melted aluminium will not react with the shielding gas, ensuring that the weld remains pure.

Although it should be noted that Argon is frequently combined with Helium, Hydrogen and Carbon Dioxide, as a mixture can provide certain properties that Argon alone cannot. For example, by combining Argon with Helium, the welder is able to achieve deeper penetration, whilst also ensuring that the weld pool remains fluid. The addition of Hydrogen will give a similar effect to that achieved by using Helium, but much stronger.

The key is to use non-oxidising gases, as these will destroy the tungsten electrode.

TIG welding is more appropriate for the more experienced welders and those that require neater welds.

Please visit our website www.engweld.co.uk for more information and for products relating to TIG welding

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