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TIG Welding
TIG Welding
SPECIFICATIONS
FOR TIG WELDING
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the standard
in tig welding
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FORM 116 AUGUST 2015
TABLE OF CONTENTS
TIG TORCH CONNECTION DIAGRAMS
Gas-Cooled Torches
Water-Cooled Torches
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WeldTRAIN
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The information in this manual represents the best judgement of CK Worldwide, Inc. and is intended for use by experienced personnel. Never operate any equipment
without carefully reading, understanding, and following all of the related safety rules and practices. CK Worldwide makes no claims, expressed or implied, as to the viability
of this information for any application or use. The individual user is solely responsible for any and all uses of the information contained herein, since CK Worldwide has no
means to confirm the correct use of, or control any of the variables to the use of any and all information herein.
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connection diagrams
2 Piece gas cooled
Valve
Valve
Lug
Dinse
Gas In
Gas In
1 piece gas-thru
Gas In
Dinse
Water Return
Water In
water cooled
NOTE: 1 quart (1 liter) per min. flow rate
Water in through water line
Water out through power cable
Dinse
Water Return
Water In
Gas In
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DCEN
DCEP
AC
CURRENT TYPE
DCSP
CURRENT TYPE
DCRP
CURRENT TYPE
ACHF
ELECTRODE
POLARITY
Electrode negative
ELECTRODE
POLARITY
Electrode positive
ELECTRODE
POLARITY
Alternating
OXIDE CLEANING
ACTION
No
OXIDE CLEANING
ACTION
Yes
OXIDE CLEANING
ACTION
HEAT BALANCE
IN THE ARC
HEAT BALANCE
IN THE ARC
HEAT BALANCE
IN THE ARC
PENETRATION
PROFILE
Deep narrow
PENETRATION
PROFILE
Shallow wide
PENETRATION
PROFILE
Medium
ELECTRODE
CAPACITY
Excellent
ELECTRODE
CAPACITY
Poor
ELECTRODE
CAPACITY
Good
DCSP mainly used on: Stainless Steel, Mild Steel, Nickel, Copper, Titanium
ACHF mainly used on: Aluminum, Magnesium
DCRP mainly used on: Thin Material
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ALUMINA
CERAMIC
SUPER CUP
PYREX
High visibility
Low thermal shock
Low impact resistance
(Pyrex)
Designed to fit
GTAW torches
Turbulent gas
flow pattern
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Gas Saver
Collet
& Collet
Body
Columnar gas
flow pattern
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GUIDE FOR SHIELD GAS FLOWS, CURRENT SETTINGS & CUP SELECTION
WELDING CURRENT (AMPS) TUNGSTEN TYPE
Cup Size
AC
Pure
AC
Thoriated
DCSP
Pure
DCSP
Thoriated
Standard Body
CFH (L/MN)
3, 4, or 5
515
5 20
515
520
58 (34)
58 (34)
58 (34)
58 (34)
.040"
(1.0mm)
4 or 5
1060
15 80
1570
2080
510 (35)
58 (34)
512 (36)
510 (35)
1/16"
(1.6mm)
4, 5, or 6
50100
70 150
70130
80150
712 (46)
510 (35)
815 (47)
712 (46)
3/32"
(2.4mm)
6, 7, or 8
100160
140235
150220
150250
1015 (57)
810 (45)
1020 (510)
1015 (57)
1/8"
(3.2mm)
7, 8,
or 10
220330
240350
1018 (59)
812 (46)
1225 (612)
1020 (510)
5/32"
(4.0mm)
8 or 10
200275
300425
375475
400500
1525 (712)
1015 (57)
1530 (714)
1225 (612)
3/16"
(4.8mm)
8 or 10
475800
475800
2035 (1017)
1225 (612)
2540 (1219)
1530 (714)
1/4"
(6.4mm)
10
325700 500700
7501000
7001000
2550 (1224)
2035 (1017)
Electrode
Diameter
.020"
(0.5mm)
For pure helium shielding gas, double flow rates shown. For argon-helium mixes with below 30% helium content, use figures shown. Always adjust gas flows to
accommodate best shielding results.
DIAMETER AT TIP
Millimeters
Inches
Millimeters
Inches
INCLUDED ANGLE
CURRENT
RANGE
PULSED CURRENT
RANGE
1.0mm
.040"
.125mm
.005"
12
215 amps
225 amps
1.0mm
.040"
.250mm
.010"
20
530 amps
560 amps
1.6mm
1/16"
.500mm
.020"
25
850 amps
8100 amps
1.6mm
1/16"
.800mm
.030"
30
1070 amps
10140 amps
2.4mm
3/32"
.800mm
.030"
35
1290 amps
12180 amps
2.4mm
3/32"
1.100mm
.045"
45
15150 amps
15250 amps
3.2mm
1/8"
1.100mm
.045"
60
20200 amps
20300 amps
3.2mm
1/8"
1.500mm
.060"
90
25250 amps
25350 amps
Vertical
85
Filler Rod
Shield Gas
15 30
Travel Direction
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TUNGSTEN extension
STANDARD PARTS
DC
Taper Length: 2-3 X DIA
AC
Ball tip by arcing on non-ferrous metal at low current DCRP (EP) then slowly
increase current to form the desired ball diameter. Return setting to AC.
TUNGSTEN GRINDING
Designation
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ISO 6848
AWS A5.12
Oxide Additive
Tungsten
WT20
EWTh-2
ThO2: 1.702.20%
2% THORIATED
Red
WP
EWP
~~~~~~
PURE
Green
WL15
EWLa-1.5
1.5% LANTHANATED
Gold
WC20
EWCe-2
2% CERIATED
Gray
WL20
EWLa-2
La2O3: 1.802.20%
2% LANTHANATED
Blue
WZ8
EWZr-8
ZrO2: 0.700.90%
0.8% ZIRCONIATED
White
LaYZr
EWG
1.5% LANTHANATED
0.8% YTTRIATED
0.8% ZIRCONIATED
Chartreuse
Tip Color
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Color Code
Characteristics
Green
Provides good arc stability for AC welding. Reasonably good resistance to contamination. Lowest
current carrying capacity. Least expensive. Maintains a balled end. Used on transformer based
machines only.
Gray
2% Thoriated
Red
1.5% Lanthanated
Gold
2% Lanthanated
Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life.
Possible replacement for thoriated.
Easier arc starting. Higher current capacity. Greater arc stability. High resistance to weld pool
contamination. Difficult to maintain balled end on AC.
Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life, high
current capacity. 1.5% possible replacement for thoriated. 2% possible replacement for Pure.
Blue
.8% Zirconiated
White
LaYZr
Chartreuse*
Excellent for AC welding due to favorable retention of balled end, high resistance to
contamination, and good arc starting. Preferred when tungsten contamination of weld is
intolerable. Possible replacement for Pure.
Best for use on automated or robotic applications. Runs cooler than 2% Thoriated with longer life.
Low to medium amperage range.
Alternating Current, AC
DCEN
Ceriated
Tungsten
Diameter in
inches (mm)
Gas Cup
(Inside
Diameter)
70% Penetration
Zirconiated
Ceriated
Zirconiated
Ceriated
Thoriated
Thoriated
Pure
Thoriated
Lanthanated
Lanthanated
LaYZr
Lanthanated
LaYZr
LaYZr
LaYZr
.040" (1.0mm)
#5 (3/8")
15 80 amps
2060 amps
1580 amps
1030 amps
2060 amps
1/16" (1.6mm)
#5 (3/8")
70150 amps
50100 amps
70150 amps
3080 amps
60120 amps
3/32" (2.3mm)
#8 (1/2")
100160 amps
140235 amps
60130 amps
1/8" (3.2mm)
#8 (1/2")
150200 amps
225325 amps
100180 amps
160250 amps
All values are based on the use of Argon as a shielding gas. Other current values may be employed depending on the shielding gas, type of
equipment, and application. DCEN = Direct Current Electrode Negative (Straight Polarity)
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Gas
Type
30 Angle
.005" FLAT
60 Angle
.010" FLAT
90 Angle
.020" FLAT
100Ar
100% Argon
75Ar-25He
75% Argon
25% Helium
50Ar-50He
50% Argon
50% Helium
25Ar-75He
25% Argon
75% Helium
100He
100% Helium
95Ar-5H2
95% Argon
5% Hydrogen
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ALUMINUM (ACHF)
METAL
GAUGE
1/16"
(1.6mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/4"
(6.4mm)
JOINT
TYPE
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET
TUNGSTEN
SIZE
FILLER ROD
SIZE
1/16"
(1.6mm)
1/16"
(1.6mm)
3/32"
(2.4mm)
3/32" (2.4mm)
1/8" (3.2mm)
3/32" (2.4mm)
1/16" (1.6mm)
1/8"
(3.2mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/8"
(3.2mm)
CUP
SIZE
4, 5, 6
6, 7
7, 8
8, 10
WELDING ALUMINUM
ARGON
ARGON
ARGON/
HELIUM
ARGON/
HELIUM
CFH
(L/MN)
PSI
15 (7)
WELDING
AMPERES
TRAVEL
SPEED
6080
12"
(307.2mm)
7090
10"
(256mm)
125145
12"
(307.2mm)
140160
10"
(256mm)
195220
11"
(258.6mm)
210240
9"
(230.4mm)
260300
10"
(256mm)
280320
8"
(204.8mm)
20
17 (8)
20
21 (10)
20
25 (12)
20
TITANIUM (DCSP)
METAL
GAUGE
1/16"
(1.6mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/4"
(6.4mm)
JOINT
TYPE
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET
TUNGSTEN
SIZE
WELDING TITANIUM
FILLER ROD
SIZE
1/16"
(1.6mm)
NONE
3/32"
(2.4mm)
1/16"
(1.6mm)
3/32"
(2.4mm)
1/8"
(3.2mm)
1/8"
(3.2mm)
1/8"
(3.2mm)
CUP
SIZE
4, 5, 6
5, 6, 7
6, 7, 8
8, 10
ARGON
ARGON
ARGON
ARGON
CFH
(L/MN)
15 (7)
15 (7)
20 (10)
30 (15)
PSI
WELDING
AMPERES
TRAVEL
SPEED
90110
10"
(256mm)
110150
8"
(204.8mm)
190220
9"
(230.4mm)
210250
7"
(179.2mm)
220250
8"
(204.8mm)
240280
7"
(179.2mm)
275310
8"
(204.8mm)
290340
7"
(179.2mm)
20
20
20
20
MAGNESIUM (ACHF)
JOINT
TYPE
TUNGSTEN
SIZE
FILLER ROD
SIZE
CUP
SIZE
1/16"
(1.6mm)
BUTT
FILLET
1/16"
(1.6mm)
3/32" (2.4mm)
1/8" (3.2mm)
1/8"
(3.2mm)
FILLET
3/32"
(2.4mm)
1/8" (3.2mm)
5/32" (4.0mm)
1/4"
(6.4mm)
1/2"
(12.8mm)
10
BUTT
FILLET
BUTT
FILLET
3/16"
(4.8mm)
5/32" (4.0mm)
1/4"
(6.4mm)
3/16" (4.8mm)
WELDING MAGNESIUM
METAL
GAUGE
BUTT
CFH
(L/MN)
PSI
5, 6
ARGON
13 (5)
15
7, 8
ARGON
19 (9)
15
10
ARGON
ARGON
25 (12)
35 (17)
WELDING
AMPERES
TRAVEL
SPEED
60
20"
(512mm)
60
115
115
100130
22"
(563.2mm)
110135
20"
(512mm)
260
10"
(256mm)
15
15
17"
(435.2mm)
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1/16"
(1.6mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/4"
(6.4mm)
JOINT
TYPE
BUTT
FILLET
BUTT
FILLET
BUTT
FILLET
BUTT (2)
FILLET
TUNGSTEN
SIZE
FILLER ROD
SIZE
1/16"
(1.6mm)
1/16"
(1.6mm)
3/32"
(2.4mm)
3/32"
(2.4mm)
1/8"
(3.2mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/8"
(3.2mm)
CUP
SIZE
4, 5, 6
4, 5, 6
8, 10
8, 10
ARGON
ARGON
HELIUM
HELIUM
CFH
(L/MN)
PSI
18 (9)
WELDING
AMPERES
TRAVEL
SPEED
110140
12"
(307.2mm)
130150
10"
(256mm)
175225
11"
(258.6mm)
200250
9"
(230.4mm)
190225
10"
(256mm)
205250
8"
(204.8mm)
225260
9"
(230.4mm)
250280
7"
(179.2mm)
15
18 (9)
15
36
(17.5)
15
36
(17.5)
15
1/16"
(1.6mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
1/4"
(6.4mm)
JOINT
TYPE
BUTT
FILLET
BUTT
FILLET
TUNGSTEN
SIZE
FILLER
ROD SIZE
1/16"
(1.6mm)
1/16"
(1.6mm)
1/16"
(1.6mm)
3/32"
(2.4mm)
BUTT
3/32"
(2.4mm)
FILLET
3/32" (2.4mm)
1/8" (3.2mm)
BUTT
FILLET
1/8"
(3.2mm)
1/8"
(3.2mm)
3/16"
(4.8mm)
CUP
SIZE
4, 5, 6
4, 5, 6
5, 6, 7
8, 10
ARGON
ARGON
ARGON
ARGON
CFH
(L/MN)
11 (5.5)
11 (5.5)
13 (6)
13 (6)
PSI
WELDING
AMPERES
TRAVEL
SPEED
80100
12"
(307.2mm)
90100
10"
(256mm)
120140
12"
(307.2mm)
130150
10"
(256mm)
200250
12"
(307.2mm)
225275
10"
(256mm)
275350
10"
(256mm)
300375
8"
(204.8mm)
20
20
20
20
TUNGSTEN
SIZE
FILLER
ROD SIZE
CUP
SIZE
1/16"
(1.6mm)
BUTT
1/16"
(1.6mm)
1/16"
(1.6mm)
4, 5, 6
1/16" (1.6mm)
3/32 (2.4mm)
3/32"
(2.4mm)
4, 5, 6
3/32"
(2.4mm)
1/8"
(3.2mm)
7, 8
ARGON
16 (6.5)
20
1/8"
(3.2mm)
5/32"
(4.0mm)
8, 10
ARGON
18 (8.5)
20
1/8"
(3.2mm)
BUTT
FILLET
BUTT
3/16"
(4.8mm)
FILLET
1/4"
(6.4mm)
FILLET (2)
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BUTT
TYPE
CFH
(L/MN)
PSI
ARGON
15 (7)
20
ARGON
15 (7)
METAL
GAUGE
FILLET
WELDING
AMPERES
TRAVEL
SPEED
95-135
15" (384mm)
95-135
15" (384mm)
145-205
11"
(258.6mm)
145-205
11"
(258.6mm)
210-260
10" (256mm)
210-260
10" (256mm)
240-300
10" (256mm)
240-300
10" (256mm)
20
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TROUBLESHOOTING GUIDE
PROBLEM
Excessive
Electrode
Consumption
Erratic Arc
Inclusion of
Tungsten or
Oxides in Weld
Porosity in
Weld Deposit
Cracking in
Welds
Inadequate
Shielding
Arc Blow
Short
Parts Life
CAUSE
SOLUTION
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Trim-Line, Max-Flo, Fail-Safe, Steady-Grip and LaYZr are
registered trademarks of CK Worldwide, Inc.
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2015 CK Worldwide, Inc. All rights reserved. S/WD # 109030 2.5K Printed 8/2015