Difference between revisions of "TIG Welder"

Revision as of 13:00, 23 January 2023

Miller 250 DX

Make: Miller

Model: Syncrowave 250DX

Serial Number: MJ430071L

Ace: Wyatt Bertis (wbertis22@georgefox.edu).

Location: Welding Shop

Safety First

Don't exceed gas pressure past specified value
Don't weld with gas off
Always use a welding helmet and proper PPE
Don't weld in wet gear or standing water
Don't unscrew regulator adjusting screw all the way out
Make sure ground clamp is connected to work

Description

TIG stands for tungsten inert gas and is technically called gas tungsten arc welding (GTAW). The process uses a tungsten electrode located in a hand held torch that delivers the current to the welding arc. The tungsten and weld puddle are shielded and cooled with argon gas. A filler rod is used to manually add material to the weld puddle. During the welding process the tungsten should never touch the work piece. When this happens you will need to remove the tungsten and regrind the tip. Depending on the material being welded, TIG welding can be performed using either AC or DC current. Some of the advantages of this type of welding include strong high quality welds and many material options. One disadvantages of TIG welding is the speed is much slower compared to some of the other welding methods.

Here is an example of TIG welding and some good basic information.

Documentation

TIG Welder User Manual

Terminology

Squarewave technology was developed by Miller Electric in 1976 to improve your weld quality and make TIG (tungsten inert gas) welding easier. Miller Squarewave technology provides arc stability when welding aluminum, prevents arc rectification and eliminates tungsten erosion.
CFH-Cubic Feet Per Hour

Balance control-The balance control is adjustable to provide additional oxide removal (more cleaning) or less cleaning based on the condition of the material being welded.

Syncro Start-This allows the choice of Soft, Standard or Hot TIG starts based on the application, lead lengths and tungsten size.

Digital welding meters-Display both amperage and voltage for viewing of the actual and preset values for greater accuracy and repeatability in your welding procedure.

Last procedure recall-Simplifies changing your Syncrowave back and forth from aluminum TIG to stainless TIG to Stick welding. One switch makes all the control panel changes.

Adaptive Hot Start-Stick welding features such as Adaptive Hot Start™ provide good arc strikes without sticking. Once welding, the DIG control makes dynamic adjustments to the welder to ensure smooth E7018 and deep penetration E6010.

Training

Operation

Here are some general setup rules of thumb:

The CFH gas setting should be roughly 2x the weld cup size. If you were to use a #7 cup the gas flow should be set to 14 CFH.
The tungsten stick-out from the cup should be no more than the cup diameter. Using a #7 cup would allow for a maximum tungsten stick-out of 7/16"

Demonstration

The demonstration consists of two parts. For the first part you will need to setup the welder and safely attempt to weld a bead. The second part will require you to show knowledge of safely using the grinder and successfully grind a point on a tungsten rod.

General Procedure

Place the fume hood over the area you will be welding
Select electrode that is adequate for your application of material
Grind electrode to a point. (This gives a smaller and more directed arc)
Insert the electrode into the collet of the torch
Attach ground clamp to table (ensure ground contact surface is clean)
Ensure the adjusting screw on the tank regulator is loose (Do not unscrew all the way)
Open cylinder valve all the way
Turn the adjusting screw (clockwise) to increase flow to 15 CFH. The gas will only flow after the pedal is depressed and will stop after the post-flow time has been reached.
Identify material type, and thickness that is going to be welded
Refer to TIG welding chart for specified adjustments, specific to your application
Clean material to remove any oxidizing and or oil residue
Turn on the welder and adjust----------
Hold the electrode in your dominant hand (ensure it can move freely)
Hold electrode about an 1/8 inch away from the metal
Using the foot pedal to control the voltage, start off with the foot pedal half way down to start a puddle on the material.
Once a puddle is started let off the foot pedal to maintain a steady puddle without burning through the material.
Once the puddle is formed, dab the filler rod into the puddle
Moving along the material, walk the electrode back and forth across the puddle while dabbing the filler into the pool

Shutting down:

Close gas cylinder valve
Back out adjusting screw on regulator (Do Not unscrew all the way)
Turn off the welder
Remove ground clamp

Certification

Canvas Quiz

Troubleshooting

Maintenance

General maintenance

The welding torch and cables should be inspected on a regular basis. Look for any signs of cracking or cuts in the cables.

Specific Maintenance Tasks

Maintenance Procedure	Frequency	Done By
Check Argon Tank Pressure	Before Use	Student/Tech
Check Coolant Flow	Before Use	Student
Inspect collet & Cup	Before Use	Student/Tech

@@ Line 4: / Line 4: @@
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   |Has name={{PAGENAME}}
+ |Has make= Miller
+ |Has model=Syncrowave 250DX
+ |Has serial number=MJ430071L
+ |Has life expectancy=
+ |Has year of manufacture or purchase=
+ |Has replacement cost=
   |Has icon=File:TIG welder.png
-  |Has icondesc=
+  |Has icondesc= Tig Welder
   |Has iconwname=
   |Has image=File:Syncrowave 250 DX TR.jpg
-  |Has imagedesc=
+  |Has imagedesc= Miller 250 DX
   |Has description=
-  |Has certification=
+  |Has certification=https://georgefox.instructure.com/courses/1270
- |Has make= Miller
+  |Has ace=Wyatt Bertis;wbertis22@georgefox.edu
- |Has model=Syncrowave 250DX
-  |Has ace=Jack Ellis;jellis17@georgefox.edu
 }}
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-The current Ace of the {{PAGENAME}} is '''{{#show: {{PAGENAME}} |?Has ace.Has name}}''' ({{#show: {{PAGENAME}} |?Has ace.Has email address}}).<br />
+Make: {{#show: {{PAGENAME}} |?Has make}}
+Model: {{#show: {{PAGENAME}} |?Has model}}
+Serial Number: {{#show: {{PAGENAME}} |?Has serial number}}
+Ace: {{#show: {{PAGENAME}} |?Has ace.Has name}} ({{#show: {{PAGENAME}} |?Has ace.Has email address}}).
+Location: {{#show: {{PAGENAME}} |?Is located in facility}}
 __TOC__
+==Safety First==
+[[File:Safety First HD2.png|left|150px]]
+* Don't exceed gas pressure past specified value
+* Don't weld with gas off
+* Always use a welding helmet and proper PPE
+* Don't weld in wet gear or standing water
+* Don't unscrew regulator adjusting screw all the way out
+* Make sure ground clamp is connected to work
 ==Description==
+TIG stands for tungsten inert gas and is technically called gas tungsten arc welding (GTAW). The process uses a tungsten electrode located in a hand held torch that delivers the current to the welding arc. The tungsten and weld puddle are shielded and cooled with argon gas. A filler rod is used to manually add material to the weld puddle. During the welding process the tungsten should never touch the work piece. When this happens you will need to remove the tungsten and regrind the tip. Depending on the material being welded, TIG welding can be performed using either AC or DC current. Some of the advantages of this type of welding include strong high quality welds and many material options. One disadvantages of TIG welding is the speed is much slower compared to some of the other welding methods.
 Here is an example of TIG welding and some good basic information.
 {{#evu:https://www.youtube.com/watch?v=IfJG4cMhIOc&list=PLhEXQudI6XCS3Rev1aaEwy0n4-68YdNTe&index=14&t=0s}}
+{{#evu:https://www.youtube.com/watch?list=RDCMUCTRI9Us8zLiywY29vsW3kKg&v=tNYmo2_DI6c&feature=emb_rel_end}}
+{{#evu:https://www.youtube.com/watch?v=KvI0177YgrA}}
 ==Documentation==
-* [https://www.millerwelds.com/files/owners-manuals/O359H_MIL.pdf Owner's Manual]
+[[Media:O359H MIL.pdf|TIG Welder User Manual]]
 ====Terminology====
 *Squarewave technology was developed by Miller Electric in 1976 to improve your weld quality and make TIG (tungsten inert gas) welding easier. Miller Squarewave technology provides arc stability when welding aluminum, prevents arc rectification and eliminates tungsten erosion.
+*CFH-Cubic Feet Per Hour
 *Balance control-The balance control is adjustable to provide additional oxide removal (more cleaning) or less cleaning based on the condition of the material being welded.
@@ Line 48: / Line 77: @@
 ====Operation====
+Here are some general setup rules of thumb:
-The SawStop table saw has a unique safety feature. A spring loaded cartridge is located in the machine. Any conductive material that makes contact with the blade causes the aluminum cartridge block to fire into the blade. The blade then stops spinning and drops down out of the way. All this happens within 5 milliseconds, helping to ensure the blade inflicts minimal damage. This galvanic response safety mechanism is great for preventing injuries but will permanently damage the blade if triggered. If the material you are cutting is conductive it will trigger the saw stop feature. Do not cut any wet lumber, pressure treated, or metal coated materials such as gold leaf with this machine. Charcoal is also conductive so any laser cut areas of lumber should not make contact with the blade while cutting.  There are a few other things to keep in mind regarding your material as well. Make sure the material you are cutting is free of all foreign objects. Do not cut materials that may have nails or screws as they will damage the blade and may cause injury to you. Also, if the material contains a loose knot it can break free and create a safety hazard.
+*The CFH gas setting should be roughly 2x the weld cup size.  If you were to use a #7 cup the gas flow should be set to 14 CFH.
+*The tungsten stick-out from the cup should be no more than the cup diameter.  Using a #7 cup would allow for a maximum tungsten stick-out of 7/16"
-If your material looks good, the next step is to set up the saw itself. When setting up the saw the blade, it should protrude no more than 1/4" above the material top. This limits the amount of blade that is exposed and makes for a good cut. You will also want to hook up the adjacent dust collector to the rear of the machine, make sure it is plugged in, and turned on. The dust collector must be used with the table saw to help keep the dust out of the air. As you make a cut, it is imperative that you keep the wood firmly against the fence to make the cut square. Therefore, you should double check to see if you are reading the right measurement on the fence, especially because the fence can be moved to either side of the blade which is why there are two distance indicators, only one of which is correct for each set up. Make sure to ask the supervisor about the available jigs because they can be helpful for specialty cuts. Once the supervisor has demonstrated the use of a jig feel free to use it in the future but do not play around with jigs you are unfamiliar with.
-After the saw is set up you are ready to cut. Turn on the saw and slowly push the material through, making sure to keep your hands away from the blade. Do not stop pushing the material until after the cut is finished unless there is an emergency, in which case, carefully use one hand or your hip to bump the off switch. Also not let go of your work piece during the cut or it will be forced back towards you.
 ====Demonstration====
-Demonstrate you can safely setup the saw and rip a board. You will then proceed to cross cut one of the remaining pieces. Remember to set the blade height so it is protruding less than 1/8" out the top of material for less exposure. When performing a rip cut the fence is used to guide the lumber into the blade. You want to make sure that the distance between the fence and blade is the width of desired cut. Mark the edge of the material when doing a cross cut so you can align the material with the blade in the sled. You can also use a miter gauge for making cross cuts but make sure the material is long enough and well supported.
+The demonstration consists of two parts.  For the first part you will need to setup the welder and safely attempt to weld a bead.  The second part will require you to show knowledge of safely using the grinder and successfully grind a point on a tungsten rod.
 ====General Procedure====
@@ Line 67: / Line 93: @@
 # Ensure the adjusting screw on the tank regulator is loose (Do not unscrew all the way)
 # Open cylinder valve all the way
-# Turn the adjusting screw (clockwise) to increase pressure to 15 CFH.
+# Turn the adjusting screw (clockwise) to increase flow to 15 CFH.  The gas will only flow after the pedal is depressed and will stop after the post-flow time has been reached.
 # Identify material type, and thickness that is going to be welded
 # Refer to TIG welding chart for specified adjustments, specific to your application
@@ Line 73: / Line 99: @@
 # Turn on the welder and adjust----------
 # Hold the electrode in your dominant hand (ensure it can move freely)
-# Hold electrode about an inch away from the metal
+# Hold electrode about an 1/8 inch away from the metal
 # Using the foot pedal to control the voltage, start off with the foot pedal half way down to start a puddle on the material.
 # Once a puddle is started let off the foot pedal to maintain a steady puddle without burning through the material.
 # Once the puddle is formed, dab the filler rod into the puddle
 # Moving along the material, walk the electrode back and forth across the puddle while dabbing the filler into the pool
 # '''Shutting down:'''
-# Close gas cylinder valve
+*Close gas cylinder valve
-# Back out adjusting screw on regulator (Do Not unscrew all the way)
+*Back out adjusting screw on regulator (Do Not unscrew all the way)
-# Turn off the welder
+*Turn off the welder
-# Remove ground clamp
+*Remove ground clamp
-==Safety==
-# Don't exceed gas pressure past specified value
-# Don't weld with gas off
-# Don't touch tip to welding surface
-# Don't weld in wet gear or standing water
-# Don't unscrew valve adjusting screw all the way out
-# Make sure ground clamp is connected to work
 ==Certification==
-[https://foxtale.georgefox.edu/moodle/course/view.php?id=31322 Foxtale Course]
+[https://georgefox.instructure.com/courses/1270 Canvas Quiz]
 ==Troubleshooting==
-If the blade appears to need sharpening ask the tech to change out the blade.
-A sign of a dull blade is as follows:
-. Burning of material
-. More resistance when cutting
-. Rough cut edges
-. Increased cutting noise
-. Increased motor noise
 ==Maintenance==
 ====General maintenance====
-Keep the saw clean and use the dust collector. There are several lubrication points on the saw that need to be checked by the tech.
+The welding torch and cables should be inspected on a regular basis. Look for any signs of cracking or cuts in the cables.
 ====Specific Maintenance Tasks====
@@ Line 124: / Line 129: @@
 !Done By
 |-
-|Lubricate mechanisms
+|Check Argon Tank Pressure
-|Semester
+|Before Use
-|Sample
+|Student/Tech
 |-
-|Clean machine interior
+|Check Coolant Flow
-|Monthly
+|Before Use
-|Tech
+|Student
 |-
-|Change the blade
+|Inspect collet & Cup
-|As Needed
+|Before Use
-|Tech
+|Student/Tech
 |}