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Optional extras for a portable DC TIG and stick inverter welder: foot control, cables, coolant, gas flow and transport.
A cylinder that is not secured can fall or be knocked over, and a falling cylinder can cause crushing injuries or damage the valve. Cylinders should be secured with a stout chain or strap, and it is normal to chain them to a wheeled trolley or against a wall.Avoid moving a cylinder by tilting it on its base and rolling it; use a trolley instead. Close the cylinder valve before moving it. Choose a trolley with a cylinder carrier that suits the cylinder size you use, and check the chain or strap before every move.
Look over the insulation on the welding and return leads for cuts, cracks, burns or exposed copper along the whole length, and check the electrode holder, plugs and clamps for damage. Insulation should be undamaged and connectors clean, undamaged and rated for the current. Damaged insulation can cause electric shock, so a damaged lead or holder should be taken out of use and repaired by a competent person or replaced.Check that the holder jaws grip the electrode firmly and that connections are tight and not discoloured by heat. Route leads where they will not be walked on or trapped.
The welding current has to return to the machine through the workpiece cable and clamp. A poor connection adds resistance, which makes the clamp and cable hot, can make the arc unstable and can make starting poor. Weak clamp spring tension, spatter, paint, mill scale and loose lugs are common causes.Clamp the return cable close to the weld, on clean metal rather than rust, because a high-resistance return path makes stray currents more likely. Do not clamp to handrails, pipes or structure unless they are part of the workpiece. Replace a clamp that runs hot or has worn jaws.
The cable, clamp and plug must be rated for at least the welding current you will use, and the machine manual or data plate shows what the machine is designed for. Connectors should be correctly rated for the current required. An under-rated cable or clamp will run hot and can cause poor welding.Cable cross-section matters more as the lead gets longer. Minimum cable sizes increase with both current and length, and return leads should be kept as short as practical. Follow the table or advice in your machine manual, and check that the plug suits the machine's output socket.
There is no single correct flow rate. The right argon flow depends on the current, electrode size and nozzle size, with higher flow generally needed for bigger nozzles and currents. Treat any guide figure as a starting point only.Too much flow can cause turbulence that pulls air into the gas stream, so raising the flow is not a cure for poor shielding. If the weld looks grey or oxidised, check for leaks, draughts and a blocked nozzle first. A flow check at the torch end can show whether the set flow is reaching the nozzle. Follow your welding procedure and the machine and torch manuals.
Use the coolant the cooler and torch maker specifies, because advice differs between makers. Some call for a purpose-made welding coolant and some for distilled water or a distilled water and glycol mix, so the manual is the only safe guide. Do not use automotive antifreeze, which can contain additives that block the narrow torch passages.Tap water can leave deposits and does not protect against freezing or corrosion. Do not mix different coolant types or brands unless the maker says it is safe, and never run the cooler without coolant. If the manual is unclear, ask the cooler supplier.