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Answers to common questions about complete air-cooled TIG torch packages with a ready-fitted cable and machine connection.
An air-cooled (gas-cooled) torch sheds its heat to the surrounding air, with a small cooling effect from the shielding gas passing through it. It needs no cooler or coolant hoses, so it is simpler and more portable. It suits lighter and intermittent work at lower currents.A water-cooled torch circulates coolant through the head and cable, which suits long, continuous or high-current welding. If you mostly weld thin to medium material in short runs, an air-cooled torch is usually the practical choice. Check the torch's rated current against your machine's output and how you really weld.
The rating is the current the torch can carry at a stated duty cycle. Duty cycle is the percentage of a 10-minute period the torch can be used at that current without overheating. A torch rated at a given current and a 60% duty cycle can weld at that current for about 6 minutes in every 10, then needs to rest.Running above the rating makes the handle and cable heat up faster, so you end up stopping more often. If you regularly weld for long periods, choose a torch with a rating comfortably above your normal working current, or consider a water-cooled type. Always follow the data plate and the maker's manual.
Look over the torch, cable and connectors before each use. Check that the cable insulation and protective hose are undamaged, there are no sharp bends or kinks, the fittings are tight, and the current connector surfaces are clean. Do not use a damaged cable or connector; have it repaired or replaced.Shielding gas should flow freely and steadily, so listen and look for obvious leaks at the fittings. HSE guidance expects the welder to carry out daily equipment checks and report defects, and employers should have a programme of regular checks as part of their risk assessment.
Choose the length that gives you enough reach to the work without leaving a lot of spare cable on the floor. A longer cable gives more freedom to move around a large job, but the extra length is more to handle, can snag, and adds weight at your wrist.Air-cooled cables are generally heavier and less flexible than water-cooled ones because the conductor has to carry the current without coolant, so an extra-flexible cable can make a noticeable difference to comfort. Avoid coiling the cable tightly while welding, and unwind it fully when working at higher current.
Poor shielding often comes down to the gas path. Leaks at fittings or a damaged hose can let air in, and too much flow can create turbulence that pulls air into the shielding gas column. Too little flow can also leave the weld pool and tungsten under-protected. The right flow depends on your cup, consumables and the surrounding conditions.Check that fittings are tight, inspect the hose, and test joints with a leak-detection fluid recommended for your gas equipment if you suspect a leak. Also check that the workpiece is clean and that there is no draught across the weld.
A flexible-head torch has a neck that can be bent to different angles, instead of a fixed rigid head. This helps you reach joints in restricted spaces and hold a comfortable wrist position, which can reduce fatigue on awkward work.A rigid head is simpler and keeps a fixed, repeatable angle, which some welders prefer for general bench work. Repeatedly bending the neck in the same place can eventually fatigue it, so bend it gently and avoid sharp kinks. Choose according to the joints you weld most often.