Welding Tips and Tricks

Hi all, just picked up a Miller Syncrowave 200 and am on my way TIG welding. Looking to weld some bike frames to start, to make things easier just going with hi-ten tubing (rather than chromoly or aluminium), using some old frames. Thickness at 0.055" thereabouts, have the amps set at 40 and using 1/16 ER70S-2 filler, having issues with the base metals separating from eachother on butt joints -- any tips? Or tubing tips in general? Cheers.

1:
Welcome to the Forum.

2:
Jody's videos are probably a great place to start.

Be prepared to be patient, everyone generally needs plenty of seat time.

Trev

Thanks! I've watch a lot of videos, especially TIG and tubing. I've gotten some welds that will pass, however it's gone south a couple of times where the tubing edges melt away from eachother rather than joining into a pool. I haven't come across any info on how to prevent that from happening. The fit is tight, what else can I watch for and do to prevent that occurrence?

Focus on one section, get a bead on it, focus on the other section, get a bead on it, then bridge the two beads.
Make sure you hold a really tight arc - a long arc will generally start to give you troubles with edges melting away pretty quickly.

40A is too low espcially if you slowly sneak up on the current. This will simply heat up the edges and they "ball" up into themselves the same way a filler rod would ball if you try to feed it into the electric arc. On a tight fit-up, try a 60-70A blast to tack them fast. The arc only needs to last 1/3 - 1/2 a sec, but it needs to be instant. If they still pull away, then the joint is not as tight as you think it is or you're still trying to go slow from a low-amperage to a high-amperage. Once they're tacked-up, you can start at a tack and the bead will flow along nicely if you are again using the right amount of current. You need to watch Jody's videos where he talks about speed-tacking. He has stated that sometimes he uses TWICE the current he would normally use to weld a particular material, and holds a super tight arc. This is something you need to experiement with to find a suitable working scenario.

Okay, thanks, great info for me to work with. I probably am ramping up too slowly and keeping the arc too long.

be aware of your touch angle as you move over the
joint that will also increase the arc length.
craig

motox wrote:be aware of your torch angle as you move over the
joint that will also increase the arc length.
craig

This is one of the largest mistakes new TIG welders do arc length and torch angle go hand and hand. Tubing is the hardest thing to learn on. I'd practice fillets and pads of beads, it will help you learn what to look for in the puddle.

Do dry runs which is practicing moving your torch around weld joints without welding. When you do these dry runs you will be able to see more since you won't have arc or helmet distractions. As you move the torch around tube in your dry run pay attention to how arc length wants to change and how torch angle wants to change. You have to learn to roll the torch in your fingers at the same time you advance the torch forward in order to maintain correct torch angle. I know you prolly are thinking how can practicing movements without welding make me a better welder this guy is whacked. What this practice does is teach you muscle memory movements (trains your brain how to move torch on instinct) and since you can see will help you realize how far out torch angle can get messed up on tubing and you can keep doing it until you agree comfortable in movements without wasting materials. Then when you go to practice actually welding joint you will be surprised how easy it becomes.

I cant remember which vid I watched of Mr tig but he was welding tubing and his torch angle just kept getting worse and worse until he long arced then stopped to reposition.His bad torch angle was caused by him not being able to rotate the torch in between his fingers. If I find it would make a great vid of how not to weld tubing.

dirtmidget33 wrote: If I find it would make a great vid of how not to weld tubing.

Any video where he attempts to weld tubing

Oscar wrote:

dirtmidget33 wrote: If I find it would make a great vid of how not to weld tubing.

Any video where he attempts to weld tubing

hehe

Oscar wrote: Any video where he attempts to weld tubing

Why stop at tubing?