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Answers for buyers choosing and running a high-current, water-cooled manual TIG torch, including long hose packs and flexible-body versions.
Water-cooled torches are designed for high-amperage work and long weld times. One major maker recommends a water-cooled torch for shop TIG jobs at 300 amps or more, though the right choice depends on the work and the torch ratings.A water-cooled torch can also be smaller and lighter at the same current rating, and its cable is lighter and more flexible, which helps reduce operator fatigue over a long day. The trade-off is that you need a cooling unit and coolant to look after, so air-cooled can still make sense for lower-current, intermittent work.
Check the maker's rating for the torch. Duty cycle is the percentage of a 10-minute period that the torch can be operated at a specific output, and running above the rated output lowers the duty cycle and heats the handle and cable faster.Water-cooled torches are generally chosen for high current and long arc-on times, but the safe figure depends on the model, the coolant flow and the temperature. Treat the data plate and manual as the authority, and choose a torch with some margin over the current you plan to use.
Match the diameter to the current you will use. A larger diameter is used for higher amperage jobs, while a smaller diameter makes arc starting easier at very low amperage settings. A 2.4 mm (3/32 inch) electrode is often suggested as a general-purpose size, covering light sheet through to thicker metal.The current range for each diameter depends on the electrode type and on whether you weld AC or DC, so follow the electrode maker's chart. Make sure the collet and collet body match the diameter you fit, as the parts are made for specific sizes.
For DC welding of steel and stainless steel, ceriated or lanthanated electrodes are generally considered acceptable, and zirconiated electrodes are generally preferred for AC. Choose the diameter to suit the current, and make sure the collet and collet body match.It is worth considering whether thoriated electrodes are justified over these alternatives, because thoriated electrodes are slightly radioactive and grinding them creates hazardous dust. Follow the electrode maker's advice for current range, and use local extraction when grinding.
A gas lens replaces the standard collet body and has fine layered screens that remove turbulence and give a smoother, laminar stream of shielding gas. Turbulent gas can draw air containing oxygen into contact with the weld pool, so a smoother flow gives better coverage, and it often lets you run a little more tungsten stick-out in tight joints.It needs the matching cup and collet body for your torch. Spatter can stick to or melt the screens and disrupt the flow, so keep it clean and replace it when worn or clogged. Check the torch manual for compatible parts, because fit differs between torch designs.
Not necessarily. Turbulent gas flow can draw air containing oxygen into the weld pool, so too much flow, or a small cup running at high flow, can cause porosity and discolouration. Draughts also disturb the shield.There is no single flow figure that suits every job. Start from the torch maker's and the welding procedure's guidance, adjust with test welds, use a gas lens if you need smoother flow, and shield the work from draughts.