Print, however, is different.  An operations manual, for example, printed hundreds of thousands of times over– with an error–  could potentially cause confusion, and none of us are immune– not even the most respected manufacturers.

We recently ran across just such a case, when a manufacturing engineer contacted us via this very blog, in response to an article we’d posted about the installation of the ceramic electrode insulator/gas distributor on the Thermal Dynamics 3A Plasma Arc Welding Torch.

Allen wrote:

The article about Plasma Arc Welding Tips from June 2007 shows a particular way to install the insulator sleeves part # 9-2240 for a Thermal PAW 3A torch. This is opposite to what my Thermal factory manual says. The manual says the collar goes towards the tip and your article says the collar goes to the torch cap. I’m confused now.

I emailed a response that included a direct link to the manufacturer’s data sheet on the 3A PAW torch which correctly shows the direction of the installation of the part.

Imagine my surprise when Allen wrote back to tell me he had called the manufacturer himself and a service tech confirmed that the manual was incorrect!

Now I’m not saying we’re always right, but I am saying it is always a good idea to double check, and ask questions.  When you’re talking about Plasma Arc Welding, there are so many variables, and the last thing you want is for you an incorrectly installed part to cause a $500 torch failure.

At Arc-Zone.com we carry a complete line of performance proven no-OEM plasma arc welding torches and replacement parts for the Thermal Dynamics(R) torches, manufactured to exacting specifications to meet your production needs.

So give us call if you’re in need of plasma arc welding torch replacement parts, accessory kits, and be sure to ask about our blanket purchase order program.  We’ll make sure you not only have your parts installed correctly, we’ll make sure you have the parts you need when you need them.

The Modular TIG torch?  Joe Welder’s FAVORITE.

He calls it “the most versatile torch on the market”.  Why?  Because you can choose from so many different torch heads at different angles and different amperages that it’s just about mind-boggling.  And you can also choose between air-cooled (WP-150) and water-cooled (WP-225) set-ups.

Do you have Weldcraft TIG Torch parts to fit a Miller DB20 water cooled TIG torch? Specifically a gas lens, collet and nozzle for .040? through .125″ diameter tungsten electrodes?

This question brings up a couple of points. First off, did you know that Miller and Weldcraft are related? Both are owned by the Illinois Tool Works (ITW). Currently all Miller TIG torches are sold as Weldcraft, taking advantage of the brand recognition of Weldcraft, a leader in the industry. Some earlier Miller torches were made by another company, but to quality standards.

Which leads me to point number two.

Most TIG torches parts are interchangeable. There are some exceptions, and certainly with some of the cheaper non-name brands you’ll find that the materials are not as good and the tolerances are, well, not tolerable…. But with quality brand names like CK, Diamondback, Lincoln, etc the parts should interchange.

I am running a Miller syncrowave 250 DX. Frequently welding cast aluminum, it pops and sizzles. I have always been looking for better cleaning techniques or a different tungsten to help get a stronger and prettier weld. There is always alot of black around the weld, and most times holes just “appear” in the weld. Any suggestions or tips to help?

That’s an interesting question — You can try a couple of things and see if it helps.

1. Use a gas lens collet body – this will improve the shield gas coverage, and allow you to run higher amperage while lowering the electrode and front-end parts operating temperature.

2. Use a product like EZ wipes to clean the rod, and the weld area just before striking the arc. First step clean weld area with clean dedicated SS scratch brush – then use the EZ wipe cleaner or equivalent.

3. Do no not use pure tungsten — Use a high-quality tungsten like our new ArcTime™ Hybrid — it’s guaranteed to make a difference or you get a refund!

4. Grind your electrode to a 45 degree angle and remove the pointed tip. Start welding. Do not ball up the tungsten it will naturally ball up. It won’t ball up like most people are used to– the big, shinny, fluid ball that’s real hard to control and very susceptible to contamination.

5. Keep your electrode tip clean. Cut-off any contamination or discolorization and re grind it.

6. Pre heat the material with an “oxidizing” oxy-fuel torch to burn of some of the debris.

6. Test argon flow rates at the torch more is not better.

7. Maintain consistent torch angle and remove any fans of drafts in the weld area.

Hope that helps!

–Jim Watson, aka Joe Welder

PS: what are your best tips for welding aluminum?

….about “spray arc transfer MIG.” I tried it with my Miller 8VS and Syncrowave 200 (on CC mode). It sounded like TIG, but I ruined a tip & nozzle. Is this type recommended “at home,” or do you need a bigger multi-processor power source, and what are the advantages?

I quickly replied:

Thanks for your question…. the spray arc transfer process is mostly used for thicker metals, and you definitely need higher voltage and current… that said, we currently (no pun intended) don’t have a lot of products and resources for MIG welding. I would highly recommend a call to Miller directly (Phone: 920-734-9821). They’ll be able to guide you better given the machine you have.

I also recommended a couple of articles, one from Miller and one from Lincoln:

http://www.millerwelds.com/education/articles/articles10.html
http://www.lincolnelectric.com/knowledge/articles/content/migweldss.asp

Dave may have felt bad that we couldn’t directly answer his question (we can usually offer a referral if there’s something we can’t answer) so he sent in this follow up via email:

Thanks for your reply. Yeah, Miller doesn’t recommend spray arc with the Syncrowave 200. Not enough output. They suggest an inverter unit like the 350 XMT, or compatible 3-phase multi-processor. I do have a question that you can answer.

As you may know, the Miller Syncrowave 200 is a somewhat advanced square wave machine. It features pulse, background adjustments for proper cleaning (AC aluminum), and a few other perks. It’s still, however, a transformer, rectifier machine. What tungsten do you, the professional, recommend for these types of machines. I’ve had good results on mild steel with 2% Thoriated, and fairly good results with pure tungsten on aluminum. Remember, it’s not an inverter machine, so I cannot adjust the “frequency” (Hz are 60 cycles) unlike the Dynasty 200 DX.

Of course a tungsten question is right up our alley. In fact, we just introduced a new, improved version of our ArcTime™ Hybrid All Purpose Tungsten, which we highly recommend for all metals and all welding machines.

Good Luck Dave, and thanks for stopping by– your t-shirt is on its way!

When I said yes, he practically erupted with joy. “Man we have been looking all over for these things. They’re like gold around here.”

He told me they used to get a similar part but the quality was inconsistent, and the availability was too. He said, “We have a job to do, and we use these nozzles to TIG weld our Titanium and other special alloys that need repair.”

He went on to say that as the nozzles became scarce, they started making them in-house from a variety of materials — Phenolic, Ceramic and then settled on a CNC machined aluminum part that was ceramic coated. “The quality was great, but they take time to make and are expensive,” he said.

The Arc-Zone.com Monster nozzle will be a great replacement for them… and they can get on with the business they are in, welding specialized aerospace materials– not tools.

This is true of a lot of the quality purge gas accessories we sell at Arc-Zone. As a master fabricator you know you can build your own trail shield, or auxiliary gas welding nozzle…. but when you’re looking for consistency, and want to focus on your core business, it’s nice to have a supplier that can offer tools so you can Weld Like A Pro™.

Fabio had just moved back to Italy though he and his wife had spent the past couple of years living on Maui. He started the truck project there, bought some equipment and soon became frustrated with the lack of available products, and tech support. He had a brand new Miller Dyanasty 200 and needed all the goods it takes to properly weld a high-performance off-road truck. Considering the number of welding equipment manufacturers in Italy, I was surprised that Fabio was unable to find the info or qualified people to help him get what he needed.

Since that first call Fabio has placed several orders and we have them delivered to his local post office. And since I promised my wife Gina that I would take her to Italy one day, I hope I’ll be able to see Fabio TIG welding in person, and take a ride in his new off-road truck!

I have a Miller Dialarc welder with a Weldcraft water cooled torch. I have been hooked up to city water and it’s worked fine for years. But I am moving my business to Klamath Falls, Oregon and my shop will get below freezing at night so I’ll need a self contained unit to cool my torch. Could you send me more information on just the cooling system/cool kit without the torch kit included as I have that….

Since Lisa already has the water-cooled torch, getting her set up with a water cooler should be pretty simple; all she’ll need is the cooler itself.

The water cooler that comes with the Cool Kit is our Tig-er cooler. It retails for about $500 plus shipping. It is a nice little cooler that runs 2 gallons. It’s solid and compact and would be a great addition to a small weld shop.

Lisa may need a water hose, and AW-431 fittings. She’ll also need the coolant which you can get from us, or from your local welding supply shop.

I got a call from a Greg — he was in need of some technical info — specifically why his TIG hoses popped, and what he can do to keep it from happening. The power cable burst just outside of the handle. “I repaired it with some tubing, heat shrink etcetera, and it just popped again and started leaking,” he said.

His local supplier’s suggestion was to buy a whole new torch package — which he did– but that did not solve the problem. I talked him through the details of his TIG set up, specifically his connections to and from the power supply and the water cooler. I concluded that his coolant pump needed to be replaced.

We always have PROCON® pumps on hand and all the mounting hardware to connect directly to the welding industries most popular water coolers (from manufacturers like Bernard, Dynaflux and ITW). We also offer a nice refurbished coolant pump. It is much simpler, efficient and cost effective than trying to repair a pump yourself. Buy a refurbished pump, with all the fittings and mounting hardware and when you return your old pump core, we give you a 25.00 core credit!

Greg was relieved that we found the problem and I said we can ship your pump to you and you’ll have it tomorrow. “I need it today I got a job to do,” he said, then added, “and I want to come up and check you guys out!”

Turns out Greg is Greg Deering President of Deering Banjo Company located in Spring Valley, California about 40 miles from us.

We had a nice visit comparing notes about our early days as a start up company and how, due to the web we have connected with so many interesting people!

Deering Banjos “The Great American Banjo Company” is the premier manufacturer of banjos. These finely crafted instruments are played by some the best musicians worldwide. Obviously there is a lot of woodwork involved and apparently some of the brasswork is TIG welded! Check out the factory here:

[flashvideo filename="http://www.joewelder.com/VIDS/deeringfactorytour.flv" /]

Each week we’ll feature real questions from real customers, and answers from our own Joe Welder. Joe, aka Jim Watson, doesn’t like to toot his own horn, but he has a tremendous amount of expertise in TIG, MIG and Plasma Arc Welding and Cutting products– you can read the details over at Arc-Zone.com or read some of the About Joe Welder posts right here.

And, if you have a welding question you’d like answered, go ahead and Click on the Contact Joe link.

If your question is featured on an Ask Joe™ post, we’ll send you a t-shirt!