Welding Tips and Tricks

In 6061, all's well to 300A with 1/8" Lan + #8 standard cup. Above that, collets + bodies start failing (mechanically). By 370A, component life 's a bit unpredictable...Does a gas lens offer any help in temp control at the contact-to-tip area, or is it better to just move up in tungsten size?

ODNT wrote:In 6061, all's well to 300A with 1/8" Lan + #8 standard cup. Above that, collets + bodies start failing (mechanically). By 370A, component life 's a bit unpredictable...Does a gas lens offer any help in temp control at the contact-to-tip area, or is it better to just move up in tungsten size?

What torch size/setup are you using?

You should call CK Worldwide and talk to them.

They do have 5/32" wedge collets, but don't have gas lenses listed, they could tell you if you call if they do have gas lenses for those. If you are not using wedge collets, you should consider switching to them, IMO, since you're using high amperage.

1-800-426-0877

Thanks guys...I'm using a 400A CK torch on a new Dynasty 400, and only have a couple bottles of time welding, so don't go thinking I know anything. The CK brass wedge collet is thermally expanding beyond its yield, leaving it crushed a bit more (and not snug in the torch when cooled) after each cycle + copper collets do the same, although to a lesser extent. I'd prefer to not have yet another size in my inventory, but I don't find any info on higher amperage TIG applications. The 1/8" CK Gas Saver does behave better, but I believe someone out there, maybe in the marine industry?, could advise me further if they wanted to. Has Jody ever posted any guidance on higher amperage TIG fundamentals? Yes, I've visited CK a few times and the crew there has given me outstanding support.

What does your cooling capacity look like?

TraditionalToolworks wrote:You should call CK Worldwide and talk to them.

They do have 5/32" wedge collets, but don't have gas lenses listed, they could tell you if you call if they do have gas lenses for those. If you are not using wedge collets, you should consider switching to them, IMO, since you're using high amperage.

1-800-426-0877

CK has 5/32 GLs. Ordered some stubby ones from either Weld Fabulous or Bakers not too long ago.

I have unlimited cooling and after 330A for 6 min, the CK torch neck is approx 65 degrees.

Maybe the question is: Can I count on a 1/8" gas lens to be reliable at the machine's limit? If not, I guess I'll move up to 5/32' and try again, as I expect most of my work will be 250A+...Manufacturers claimed duty cycle is cont. @ 250A, 6 min @ 300, and 2 min @ 400A, but I haven't had one over-temp yet.

ODNT wrote:I have unlimited cooling and after 330A for 6 min, the CK torch neck is approx 65 degrees.

Maybe the question is: Can I count on a 1/8" gas lens to be reliable at the machine's limit? If not, I guess I'll move up to 5/32' and try again, as I expect most of my work will be 250A+...Manufacturers claimed duty cycle is cont. @ 250A, 6 min @ 300, and 2 min @ 400A, but I haven't had one over-temp yet.

I have never seen any charts that state greater than 250 amps for a 1/8" electrode, of constant current. For pulsed I have seen charts that state up to 350 amps, but not for constant current.

As I mentioned, I would call CK Worldwide, talk to the source of the most common tig consumables. They are great people and will steer you in the right direction. They may have 3/16" tungsten also, I've seen some available, just that they don't list any on their site. But without a call to them you'll never know.

If you explain to them what you're doing, they can give you guidance to what consumables you should use. Doesn't cost you anything to call, it's an 800 number.

You are likely to get a lot of opinions on what you should or shouldn't do, many from people that have never welded at that amperage. Guaranteed CK Worldwide has customers welding at the highest amperage used with tig to date.

It really has to do with how much EP you are running. If only at 15-20% EP or less, you can weld with a 1/8" tungsten at above 300A no problem. Once the EP gets over 25-30% or so, you may start having issues with a 1/8" tungsten before you even get to 300A and will have to step up to 5/32". Of course, all machines have different personalities, so your mileage may vary.

TT - Yep, CK is good. But I did try them first and it's always a try-and-see at higher Amps as there just isn't the examples from individual experience.

Spartan - I think I'll go for the 5/32" lens before a 3/16", as I'm getting the feeling others would move away from the 1/8" anyway...Millers chart shows the 5/32" starting at 160A, but even they won't part with specifics above the Dynasty 280 range.

Oh well, thanks for the help guys!

ODNT wrote:Millers chart shows the 5/32" starting at 160A

There is a lot to learn from independent R&D and the resulting empirical evidence. Using adjustable hot-start, and with the correct tip geometry, I've made a 5/32" tungsten hold a steady DC arc at 4 amps using my Invertig 400.

Oscar - For what it's worth, I get solid starts every time at 3A with any point, but need 7A to deburr .030" SS sheet metal.

I see you've been involved in this for a while, is it really that unusual to TIG above 300A? No one seems to have actual experience, only a bead here or there.

I'll refrain from posting pics/vid until I'm sure it's not bad manners...

ODNT wrote:Oscar - For what it's worth, I get solid starts every time at 3A with any point, but need 7A to deburr .030" SS sheet metal.

I see you've been involved in this for a while, is it really that unusual to TIG above 300A? No one seems to have actual experience, only a bead here or there.

I'll refrain from posting pics/vid until I'm sure it's not bad manners...

I'd say it's pretty rare for someone to discuss it in an online forum unless someone is TIG'ing aluminum near 1⁄2" base material thickness. I don't have actual experience as per your definition, just a bead here and there. I'm just a hobbyist.

Just an update:

That 1/8" CK gas lens allows 7/16" stick out at 330A and 20CFH in clean 3/8" 6061, moving the hot section away from the Collet/Body enough to live in the CK18 torch. I'll move up to a 5/32" tungsten/gas lens when parts arrive and close out this thread with the results at 400A. Thank you for posting your responses!