Torches, torch heads, remote controls, earth leads and trolleys for a multi-voltage AC/DC TIG inverter: how to pick the right part and look after it.
What checks should I make on the torch, leads and remote control before welding?
The welder is responsible for daily equipment checks and reporting defects. Look at the insulation on the torch, cables, plugs and clamps for cuts, burns or crushing, check that connectors are clean and undamaged, and check the pedal or hand control cable.
Do not use anything with damaged insulation or loose, hot connectors. A damaged cable should be replaced by a competent person rather than repaired with insulating tape, and kit you are unsure about should be taken out of use. Switch off and unplug the machine before inspecting plugs or changing torch parts.
What should I check on the earth return lead and clamp?
All the welding current passes through the earth lead and clamp, so they matter as much as the torch. Check that the insulation on leads, plugs and clamps is undamaged, that the conductor is thick enough for the current, and that connectors are clean and rated for it.
Fit the clamp to clean bare metal, as dirt, rust or paint cause poor contact and heating. Hot connections and a stumbling arc are warning signs of too much resistance. Replace a clamp with a weak spring, loose connection or burnt jaws rather than carry on, and do not use a lead that is too thin for the current you are welding at.
Does the length or coiling of welding leads matter?
Yes. Long or undersized leads add resistance and voltage drop, so keep the return lead only as long as you need and use a larger cable size for long runs. Remember the current travels out and back, so the whole circuit is the work lead and the torch lead together.
Do not coil surplus cable tightly, particularly at high current, because a tight coil cannot shed heat as well as a cable laid out and the insulation can overheat. Lay leads out loosely where you can, and avoid winding them around a trolley or gas cylinder.
Which tungsten should I use for AC and DC, and what about thoriated types?
Ceriated and lanthanated tungsten are common choices for both DC and AC welding, and the best type depends on your machine and work. Your machine's manual and the tungsten supplier's data will tell you what suits your work.
Thoriated tungsten contains a slightly radioactive oxide. Grinding is the main hazard because it releases fine dust that can be breathed in. Use a dedicated grinder with local dust extraction, wear a filter mask, collect and seal the dust, and consider whether thoriated electrodes are justified over the alternatives. Make sure your risk assessment covers grinding.
Should I choose a gas-cooled or water-cooled torch for AC and DC TIG?
Gas-cooled torches are cooled by the shielding gas and cable. They are lighter and simpler, and they usually suit lower current and shorter welds. Water-cooled torches have extra hoses and need a separate cooling unit, but they generally carry more current for longer without overheating.
Base your choice on the highest current you will weld at, how long you weld without a break, and whether the machine has a cooler connection. Torch ratings are normally quoted with a duty cycle, which is the share of a ten-minute period the torch can run at that current, so compare the figure for the current you will really use. The rating can also differ between AC and DC, so keep within the maker's limits.
How do I find out which torch, remote control or lead fits my machine?
Start with the data plate and the manual. They show the maximum welding current, the supply details and which accessories and connections the machine is designed for. Note the connector types on the front panel: the plug-in size for the welding current, the gas fitting and the remote control socket.
Makers publish lists of which remote controls and accessories suit which machines, so use the list for your machine. Plugs that look similar may not be wired the same way, and pin layouts differ between makers, so a physical fit is not proof of compatibility. Confirm the match with the maker's accessory list or ask our team before ordering.