Welding Tips and Tricks

Chips O'Toole wrote:It seems like new complications keep popping up. It looks like a welder's duty cycle doesn't apply to the torch. Is that correct?

Correct

Chips O'Toole wrote: I started using a timer to make sure I don't go longer than 6 minutes, and I set it for 4 minutes between welds, but the torch is still hot when I start up again. I'm nowhere near the welder's maximum amperage.

So remind me, you're using an air cooled torch?

I bought some A36 (hot rolled) flat stock to try and duplicate your situation, hope to post something soon

Chips O'Toole wrote:It seems like new complications keep popping up. It looks like a welder's duty cycle doesn't apply to the torch. Is that correct?

I started using a timer to make sure I don't go longer than 6 minutes, and I set it for 4 minutes between welds, but the torch is still hot when I start up again. I'm nowhere near the welder's maximum amperage.

Before I started using water cooled torch I would hang the air cooled torch in front of the welder cooling fan (huge fan on my machine).

A regular fan works too.

I cooked (ruined) a few wp-26 torches on AC current before I switched to water cooled.

If you are using a 9 series torch, it'll over heat fast.
17 or 26 series are much better for heat.

For God's sake, don't spend money on steel to fix my issues. I think I'm just slow, with bad technique. And obstructing the pedal didn't help.

I have the air-cooled 17 torch that came with the welder. I just assumed the torch's duty cycle was equal to or greater than the welder's. Guess I can forget about that. I haven't melted the torch or anything, but it does seem like it gets too hot to continue using, well within the welder's duty cycle.

People complained about the torch the AlphaTIG originally came with. I don't know if I have that torch, or if they fixed the torch by the time I got my machine (March 2017).

It's not a problem. Just new information to keep in mind.

I think welding practice is harder on everything, because you're doing as much as you can, instead of setting up a typical job and finishing in a few minutes.

Chips O'Toole wrote: I think welding practice is harder on everything, because you're doing as much as you can, instead of setting up a typical job and finishing in a few minutes.

Ha! Define "typical" and "a few minutes"

Keep in mind that just because a torch is hot doesn't mean you have exceeded it's duty cycle. But one thing you do have to worry about is over-heating the power cable if it is a 1pc power cable. It's usually only a problem when doing AC welding, but even DC welding can get it very toasty.

Chips O'Toole wrote: I just assumed the torch's duty cycle was equal to or greater than the welder's.

I'm only familiar with Lincoln torches, but they specify their duty cycle. If you look at this product brochure and search for the word duty, you'll find the duty cycles for each of the torches in terms of 60% at some current. If you can figure out who makes your torch, you can probably find the same information from the manufacturer. With a 17 torch I would guess your torch has a higher duty cycle than your welder in terms of doing damage to the torch, but you might need a heavier glove on your right hand to be able to use the torch at it's rated duty cycle. You might also try bumping your pedal a few cycles while your welder is resting, that will help cool the torch.

I don't actually know how to tell when a torch is too hot. I assume the first warning sign isn't a molten or flaming torch.

A 17 air cooled torch is rated for use at 150 amps but even at 130 -150 amps I've melted down a few of them. One melted enough that the brass inserts became loose in the body. I've also burnt up one at the threaded connections. Both times I noticed a stuttering arc. Oh and it was kinda hot to the touch.

Chips O'Toole wrote:For God's sake, don't spend money on steel to fix my issues...

LOL! I can assure you of two things.

First, Richard will most certainly get his own use out of this steel.

Second, he and we will likely learn something in the process. Even those of us who've been at this 30+ years like to learn something every day. If I'm not learning, it means I no longer find it interesting, and it's time to move on to something else. In my case, that would likely be the grave.

Steve