TIG Welding User Guide

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Shop Area: Metal Shop

Tool: TIG Welding

Requires in-person training: Yes 

Procedure Number

UG 130-04, Rev. 1

Date

2/5/2021


GENERAL

AlphaTIG 200x welder is a tungsten-inert gas welder. Best materials to weld:

  • Aluminum
  • Stainless steel
  • Alloy steel
  • Thin-gauge materials

The 200X features a pulse feature allowing adjustments to control the amount of heat generated.   The welder can be used in AC or DC mode, or as a stick welder.

TIG Alpha 200X Welder.png 

SAFETY

  • Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching.
  • Wear approved welding gloves and jacket.
  • Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
  • Before operating equipment, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove all loose clothing and confine long hair.
  • Closed toe shoes are required when working in a shop area.
  • Turn off all equipment when not in use.
  • Do not use worn, damaged, undersized, or poorly spliced cables.
  • Do not drape cables over your body.
  • Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
  • Do not connect more than one electrode or work cable to any single weld output terminal.
  • Do not touch hot parts bare handed.
  • Allow cooling period before working on gun or torch.
  • Keep your head out of the fumes. Do not breathe the fumes. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
  • Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
  • Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
  • Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.

REFERENCE

PROCEDURE

DC TIG welding

1. Turn the power switch ON, this is located on the back of the unit, the digital current meter and the cooling fans will turn on.

2. Open the valve on the gas cylinder and regulate the flow meter to the required value ( 15 to 20 cfh).

3. If the AC/DC switch is on DC mode, and in TIG function, welding such metals as stainless steel, iron and copper is possible. When in AC mode aluminum welding is possible

4. When torch/pedal switch is in the torch position the arc will be controlled by the torch switch. When the switch is in the pedal position the arc will be controlled by the pedal.

5. When the pulse switch is in the on position, you will need to set the pulse frequency for desired effect.

6. The pulse amps are a percentage of the main amps and this is to be set to what the required amps are for the type of material being welded.

7. When you press the control button on the torch this will activate the solenoid valve and the high frequency in the machine, a sound will be heard with the argon gas flowing through the torch. If switched to pedal operation the pedal activates the flow and high frequency start.

8. The tungsten electrode of the welding torch is 2-4 mm from the work piece.

9. Using the Post flow control will protect the weld while it cools down by continuing the gas flow after the arc stops.

10. When 2T/4T switch is in the 2T position only the main amps will operate along with the post flow. In 4T position arc start amps and end amps will work. Do not use 4T function with the foot pedal.

11. When in 4T mode you press and release the switch an arc will start and continue to run until you press and release the switch again.

AC TIG welding

1. If AC/DC switch is in AC mode, this process will weld aluminum and magnesium. All other metals require DC mode.

2. The AC balance (cleaning action) is used for oxidized aluminum. Care must be taken in choosing the correct tungsten size, as too much cleaning action can overheat the tungsten and melt it.

3. The AC frequency mode can alter the width of the arc and can create a narrow or wider bead depending on the setting (125Hz is a common setting). Having a higher frequency can be of help when working with thinner aluminum as it creates a smaller weld bead and using less gives a softer wider bead.

DC STICK welding (SMAW)

1. For stick operation (MMA), select stick function on the TIG/MMA switch. Connect the stick electrode holder to the negative port (-) and the ground dinse is connected to the positive port (+), these can be reversed with the electrode holder in the positive port (+). The diagram shows electrode negative, this gives a softer flowing bead for most rods.

TROUBLESHOOTING

TBD

                                                        END OF THE PROCEDURE