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Practical answers on choosing, setting up and looking after a complete water-cooled TIG torch package.
A gas lens replaces the standard collet body with one that holds fine mesh screens. These smooth the shielding gas into a more even, laminar flow, where a standard collet body simply has side ports. That helps most when you need a longer tungsten stick-out, for example to reach into a joint, and it suits critical or high-quality welds.On short stick-out and non-critical work you may see little difference. A gas lens needs the matching collet, cup and collet body for your torch series, so check the parts list in the manual before ordering.
Ceriated or lanthanated electrodes are generally accepted alternatives to thoriated ones, especially on DC, while zirconiated is usually preferred for AC. Thoriated electrodes are slightly radioactive, and the main hazard is the fine dust made when grinding the tip. Where thoriated electrodes are used, grind them on a dedicated wheel with local dust extraction, and keep eating and drinking away from the grinding area.Choose the diameter to suit your welding current, following the electrode maker's guidance. Too small an electrode overheats and erodes, and too large a one can make starting and arc stability worse.
A quick daily check catches most torch faults before they damage the weld or become a hazard. Check that the gas nozzle and tungsten are intact and held tightly, and that shielding gas flows freely and steadily. Look over the torch and cable insulation for damage, check the cable has no sharp bends, and make sure the connectors are tight and the current connection surfaces are clean.If you see damaged insulation, a cracked handle or a weeping hose, stop and have it repaired or replaced rather than taping it up. Follow the maker's maintenance schedule for anything further.
Water-cooled torches are normally chosen for higher currents and long arc-on times, where an air-cooled torch would run hot. They carry the heat away through the cooling circuit, which allows a lighter and more flexible handle and cable for a given current. The trade-off is that you need a cooler unit, extra hoses and coolant, so the set-up is less portable.Air-cooled torches are usually lighter and simpler for lower currents and intermittent welding. Check the rated current and duty cycle on the torch data plate against how you will really weld. Running above the rating shortens the duty cycle it can sustain.
Yes. A high-frequency start adds a high-voltage pulse on top of the machine's open-circuit voltage to ignite the arc. It can pass through gloves, tape and thin screens, so never assume that a repaired or taped torch is safe.Switch the power source off before changing the tungsten or the gas nozzle, so an accidental press of the torch switch cannot start the arc. Wear dry, undamaged leather gloves and insulating footwear, keep your body out of the welding circuit, and avoid working in damp conditions. Do not use a torch with damaged insulation. Follow the machine manual and your risk assessment.
Yes. The arc gives off ultraviolet and infrared radiation that can cause arc eye, a painful injury to the front of the eye that often appears a few hours after exposure. Use a welding helmet or shield with a filter that meets the relevant British and European standards, and screen the area so bystanders are protected too.TIG produces little visible fume, but ozone can irritate the airways, particularly when welding stainless steel and aluminium. The HSE advises using suitable extraction and, where fume is not fully controlled, respiratory protective equipment. Your risk assessment should decide the right controls.