TIG welding is one of those upper echelon fabrication skills that many home hobbyists hope to learn. Unlike MIG, stick, or any other form of welding, Tungsten Inert Gas (TIG) welding uses a non consumable tungsten electrode to deliver the arc. Only the material to be welded and the filler rod are introduced into the weld puddle, so you can weld almost any metal with the TIG process.
Sounds good, right? So what's the catch? Why doesn't everybody and their sister have a TIG welder in their bedroom? Well, for the most part TIG welders are big, complicated, expensive monsters that can weigh up to 500 pounds and that take a degree in molten metalology to set up. Nowadays there are much smaller inverter-based machines that offer a whole slew of features and options in a lightweight, portable package, but again their complicated setup and price are prohibitive to the regular hobbyist.
Enter Miller Electric's Diversion 165. With a welding range of 10-165 amps, an easy single-dial setup, and a price that won't put you in the poor house, it's the perfect weapon for the enthusiast looking to take his welding to the next level. No need to worry about setting the initial amperage, background amperage, final slope time, final amperage, post flow, and so on. The Diversion 165 does that all for you based on the material type and thickness you're welding. So check out a few highlights with us as we explore TIG welding with Miller's newest creation.
The Diversion 165 comes complete...
The Diversion 165 comes complete with everything you need to get welding including the regulator, 12.5 foot LS17 Weldcraft torch, a 12-foot ground clamp, and 230 volt power cord. We ordered the optional foot control and Miller's Performance Series helmet. Miller even includes its informative TIG Welding For Dummies book, DVD, and blueprints to build your own welding cart.
The 150-amp air-cooled Weldcraft...
The 150-amp air-cooled Weldcraft torch comes fully loaded. From bottom to top are the torch, tungsten, collet, collet body, and ceramic gas cup. The tungsten is 2 percent cerium rather than pure tungsten. The easy way to tell is 2 percent cerium, or EWCe-2 has an orange band and pure tungsten, or EWP has a green band. The orange has better start characteristics and higher current capacity than green.
You'll need a bench grinder...
You'll need a bench grinder with a fine grit or diamond stone to prepare your tungsten. Taper the tip to 2 to 2 1/2 times the diameter of the tungsten. Grind lengthwise as shown to prevent a wandering arc. If you grind with the tungsten perpendicular to the stone it creates spiral grooves in the tip which will allow the arc to go all over the place. If you're welding aluminum you'll want to grind a small land in the tip of the tungsten point so it's not pencil-sharp.
Here's the type of tungsten...
Here's the type of tungsten prep you're looking for. You don't want the tungsten to extend more than the diameter of the gas cup you're using. A good rule of thumb is to have it protrude 3/16- to 1/4-inch from the cup.
The LS17 Weldcraft TIG torch...
The LS17 Weldcraft TIG torch is a quality piece that includes a built-in amperage control which is good for awkward out of position welding like on a roll cage or anywhere you can't easily put a foot controller. It's simple to operate. You depress the red button to start the arc and then dial up the amperage with the wheel. Hit the button again to stop welding.
You'll need to pick up a tank...
You'll need to pick up a tank of Argon gas and filler rod before you begin welding. Straight Argon can be used for welding either aluminum or steel and is less expensive than Helium. There are numerous filler rod types and diameters, but 1/16-inch works well for most stuff the average 4x4 guy will be welding.
Although the Weldcraft torch...
Although the Weldcraft torch controls are very easy to use, we're a bit old school and still wanted the foot actuated amperage controller. To use the optional remote foot control, just plug it into the front of the welder and the torch remote functions are bypassed automatically.
With the tungsten prepared...
With the tungsten prepared and the torch readied, it's a simple three step process to begin welding. First, turn on the machine power, select your material type, and then dial in the amperage gauge based on the material thickness that you're welding. The machine takes care of the rest
One thing you'll need to remember...
One thing you'll need to remember when TIG welding is that the material to be welded needs to be completely clean and grease free. For the best results it's a good idea to remove the protective coating most mild steel is shipped with.
The best advice we've been...
The best advice we've been given is to practice a lot and don't get discouraged. There's a lot of art in the TIG welding process. You need a decent eye to watch your puddle and vary the amperage and a good sense of timing and control to move the torch and add filler. However, the increased control and the ability to weld just about any type of metal are well worth the effort once you get the hang of it.