How To Tig Weld With A Mig Welder
Are you interested in learning how to TIG weld, but don’t have access to a TIG welder? Don’t worry! It’s actually possible to TIG weld using a MIG welder, with a few modifications and techniques. In this article, we will guide you through the process of TIG welding with a MIG welder, so you can expand your welding skills without investing in new equipment.
What is TIG welding?
TIG welding, or tungsten inert gas welding, is a precise and versatile welding process that is commonly used to weld thin sections of stainless steel, aluminum and other non-ferrous metals. It requires a TIG welder, which uses a non-consumable tungsten electrode to create an arc that melts the base metal and forms a weld.
But what if you only have access to a MIG welder?
The MIG welding technique
MIG welding, or metal inert gas welding, is a popular welding process that uses a consumable wire electrode to form a weld. It is typically used for thicker materials and is easier to learn compared to TIG welding. However, with some adjustments and modifications, you can use a MIG welder for TIG welding.
So, how is it done?
What is TIG welding?
TIG welding, or Tungsten Inert Gas welding, is a type of welding process that uses a non-consumable tungsten electrode to produce the weld. Unlike MIG welding, which uses a consumable electrode, TIG welding requires the welder to manually feed a filler rod into the weld pool.
TIG welding is known for its precision and the high quality of the welds it produces. It is commonly used in industries such as aerospace, automotive, and fabrication, where a clean and aesthetically pleasing weld is required. TIG welding can be used to weld a variety of metals, including stainless steel, aluminum, and copper alloys.
One of the key advantages of TIG welding is its ability to create welds without the use of a flux. The inert gas, typically argon, used in TIG welding serves to shield the weld and prevent contamination, producing a clean and strong weld. Additionally, the control provided by TIG welding allows for precise heat input, minimizing distortion and reducing the need for post-weld finishing.
How does TIG welding work?
In TIG welding, the tungsten electrode is used to create an electric arc with the workpiece, generating the heat required to melt the metal and form the weld. The filler rod is manually fed into the weld pool, gradually adding material to strengthen the joint.
The tungsten electrode used in TIG welding is non-consumable, meaning it does not melt during the welding process. Instead, it remains intact and is continuously used to create the arc. The arc is shielded by the inert gas, preventing oxidation and ensuring the integrity of the weld.
TIG welding requires a high level of skill and control from the welder, as it involves precise movement of the torch and filler rod. It is often used for applications that require a high degree of weld quality and visual appeal, such as welding delicate or thin materials.
Overall, TIG welding is a versatile and reliable welding process that offers excellent control and high-quality welds. It is widely used in various industries and is a valuable skill for any professional welder.
Advantages of using a MIG welder for TIG welding
While TIG welding is typically done using a TIG welder, it is possible to use a MIG welder for TIG welding with a few modifications. Although it may seem unconventional, there are several advantages to using a MIG welder for TIG welding.
1. Cost savings: MIG welders are generally more affordable than TIG welders, making them a cost-effective option for those who already have a MIG welder but need to perform TIG welding occasionally. This can save you money by eliminating the need to purchase a separate TIG welder.
2. Versatility: MIG welders are known for their versatility, as they can be used to weld a variety of materials including aluminum, stainless steel, and mild steel. By adapting a MIG welder for TIG welding, you can expand the range of materials you can work with using TIG welding techniques.
3. Easy setup: MIG welders are relatively easy to set up compared to TIG welders. With a few modifications to your MIG welder, such as adding a TIG torch and regulating gas flow, you can quickly convert it into a TIG welding machine. This means less time spent on setup and more time on welding.
4. Increased welding speed: MIG welders are known for their high welding speeds, making them ideal for projects that require efficiency. By using a MIG welder for TIG welding, you can potentially achieve faster welding speeds, allowing you to complete projects more quickly.
5. Simplicity: TIG welding can be more complex and require greater skill compared to MIG welding. By using a MIG welder for TIG welding, you can simplify the process and reduce the learning curve, especially for those who are already experienced with MIG welding.
While MIG welders may not have been designed specifically for TIG welding, they can still be a viable option for those who want to perform TIG welding without investing in a separate TIG welder. With some modifications and adjustments, a MIG welder can provide the benefits of TIG welding while capitalizing on the advantages of a MIG welder.
How to set up a MIG welder for TIG welding
If you want to try TIG welding but don’t have a TIG welder, you can actually use your MIG welder with a few modifications. Here’s how you can set up your MIG welder for TIG welding:
1. Switch to DC electrode negative (DCEN)
TIG welding requires DC electrode negative (DCEN) polarity, which means the electrode or tungsten is connected to the negative terminal. Most MIG welders default to DC electrode positive (DCEP) polarity, so you’ll need to switch the polarity. Check the user manual for your specific welder on how to do this, as the process may vary.
2. Replace the MIG gun with a TIG torch
Remove the MIG gun from the welder and replace it with a TIG torch. The TIG torch typically has a smaller and more precise gas nozzle compared to the MIG gun. Make sure to properly connect the TIG torch to the welder following the manufacturer’s instructions.
Some MIG welders may require additional adapters or conversion kits to properly connect the TIG torch. Check with the manufacturer or a welding supply store if you’re unsure about compatibility.
Note: Some MIG welders may have a built-in TIG welding mode or feature, which eliminates the need to switch the polarity or replace the torch.
3. Adjust the gas flow and pressure
TIG welding requires a steady flow of shielding gas to protect the weld from contamination. Adjust the gas flow and pressure according to the recommendations of your specific TIG welding setup. The gas flow typically ranges from 10 to 20 cubic feet per hour (CFH).
You may need to install a gas solenoid valve if your MIG welder doesn’t have one. The solenoid valve controls the flow of shielding gas and ensures it only flows when the torch trigger is pressed.
Note: TIG welding typically requires a high-purity shielding gas like argon.
4. Set the correct welder settings
Lastly, adjust the welder settings to match the requirements of TIG welding. This includes setting the amperage, pulse frequency, and any other parameters specific to TIG welding. Refer to the user manual of your welder for the recommended settings or consult a welding professional if you’re unsure.
Once you’ve made all the necessary modifications and adjustments, you’re ready to start TIG welding with your MIG welder. Remember to practice proper TIG welding techniques and safety precautions.
Step-by-step guide to TIG welding with a MIG welder
Step 1: Prepare your materials
Before you start TIG welding with a MIG welder, gather all the necessary materials. This includes safety equipment such as welding gloves, a welding helmet, and welding apron. Additionally, ensure that you have the appropriate TIG welding accessories, including a TIG torch, tungsten electrode, and filler rod.
Step 2: Set up your MIG welder
Adjust the settings on your MIG welder to make it suitable for TIG welding. Switch the MIG gun with a TIG torch, and ensure that the gas flow rate is appropriate for TIG welding. Set the welding machine to DC mode for TIG welding, as TIG welding typically requires a direct current power supply.
Step 3: Prepare the workpiece
Clean the surface of the metal workpiece that you will be welding. Use a wire brush or grinder to remove any rust, scale, or dirt. Additionally, use acetone or a similar solvent to degrease the surface. This will ensure better weld quality and prevent contamination.
Step 4: Insert the tungsten electrode
Insert the tungsten electrode into the TIG torch. Make sure it is securely tightened and protruding the appropriate length for the desired weld thickness. Refer to the welding specifications or consult an expert to determine the correct electrode size and protrusion length for your project.
Step 5: Set the gas flow rate
Adjust the gas flow rate on your MIG welder to ensure proper shielding during TIG welding. It is crucial to maintain a consistent flow of argon gas to protect the weld from oxidation and atmospheric contamination. Refer to the welding guidelines for the recommended gas flow rate for your specific welding application.
Step 6: Start TIG welding
Position the TIG torch close to the workpiece at a slight angle. Press the foot pedal or use the hand control to initiate the arc. Move the torch steadily along the joint, maintaining a consistent distance and angle. Control the filler rod with your other hand, adding it as necessary to create the desired weld bead.
Step 7: Practice and improve
TIG welding with a MIG welder may take some practice to achieve desired results. Experiment with different settings, techniques, and materials to improve your skills. Be patient and continue to refine your TIG welding technique to achieve clean and high-quality welds.
Remember, while TIG welding with a MIG welder is possible, it may not provide the same level of control and precision as a dedicated TIG welding machine. Consider investing in a TIG welder if you plan on pursuing TIG welding projects more extensively.
Troubleshooting common issues in TIG welding with a MIG welder
TIG welding with a MIG welder can provide numerous benefits, but it’s not without its challenges. Here are some common issues that you may encounter during TIG welding with a MIG welder and how to troubleshoot them:
1. Poor weld penetration
If you’re not getting the desired weld penetration, there are a few potential causes to consider:
- Check the amperage setting on your MIG welder. If it’s too low, increase the amperage to achieve better penetration.
- Ensure that you’re using the correct type and size of tungsten electrode. Different materials and thicknesses require specific electrode types and sizes for optimal penetration.
- Inspect the gas flow. Insufficient shielding gas coverage can lead to poor penetration. Check for leaks in the gas line and ensure that the gas flow rate is sufficient.
2. Excessive heat and distortion
Dealing with excessive heat and distortion is a common challenge in TIG welding with a MIG welder. Consider the following troubleshooting steps:
- Reduce the amperage to lower the heat input. Experiment with different amperage settings to find the right balance between penetration and heat control.
- Use a smaller tungsten electrode size. A smaller electrode diameter can help concentrate the heat and minimize distortion.
- Implement proper pre-heating and post-heating techniques. Pre-heating the material before welding and applying controlled cooling after welding can help reduce distortion.
3. Tungsten contamination
Contaminated tungsten electrodes can result in poor weld quality. Here’s how to deal with tungsten contamination:
- Ensure that the tungsten electrode is clean before each use. Use dedicated equipment, such as a dedicated grinder, to prepare and sharpen tungsten electrodes.
- Avoid touching the tungsten electrode with bare hands or using it to strike an arc, as this can introduce contaminants.
- Monitor the gas flow and ensure that the shielding gas is not contaminated. Contaminated gas can cause tungsten electrode contamination.
By troubleshooting these common issues, you can improve your TIG welding results with a MIG welder and achieve better weld quality and performance.
Maintenance tips for TIG welding with a MIG welder
TIG welding with a MIG welder requires regular maintenance to ensure optimal performance. Here are some maintenance tips to keep in mind:
- Clean the welding gun regularly: The welding gun can accumulate dirt, dust, and other particles during welding. It’s important to clean the gun regularly to prevent any blockages or malfunctions. Use a wire brush or compressed air to remove any debris.
- Inspect the consumables: The consumables, such as the electrode and nozzle, should be inspected regularly for any signs of wear or damage. Replace any worn out or damaged consumables to ensure proper welding results.
- Check the gas flow: Proper gas flow is crucial for TIG welding with a MIG welder. Check the gas regulator and ensure that the gas flow is consistent and at the recommended pressure. Any leaks or irregularities should be addressed immediately.
- Keep the welding cables in good condition: Inspect the welding cables for any fraying or damage. Damaged cables can affect the quality of the weld and even pose a safety risk. Replace any damaged cables and ensure that they are properly connected.
- Monitor the cooling system: If your MIG welder is equipped with a cooling system, regularly check the coolant levels and ensure that the system is functioning properly. Maintaining the proper cooling system can help prevent overheating and extend the life of the welder.
- Calibrate and adjust settings: Periodically calibrate and adjust the settings of your MIG welder to ensure optimal performance. Refer to the user manual for instructions on how to calibrate and adjust the machine.
- Store the welder properly: When not in use, store the MIG welder in a clean and dry environment. Protect it from dust, moisture, and other elements that can cause damage. Proper storage can help extend the lifespan of the welder.
By following these maintenance tips, you can ensure that your TIG welding with a MIG welder remains efficient and produces high-quality welds.
Questions and answers
What is TIG welding?
TIG welding, or tungsten inert gas welding, is a type of welding that uses a non-consumable tungsten electrode to produce the weld. It is known for its precision and high-quality welds.
Can I use a MIG welder for TIG welding?
No, a MIG welder cannot be used for TIG welding. TIG welding requires a different type of welding machine, known as a TIG welder, which has a different setup and controls specifically designed for TIG welding.
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