Marshall Dynabolt 250 Amp AC/DC Tig Welding Set
| TIG Welding Set (Marshall Dynabolt) | |
|---|---|
 | |
| Model | Marshall Dynabolt 250 Amp AC/DC Tig Welding Set |
| Sub-category | Metalworking |
| Status | Awaiting EX2 Setup |
| Last updated | 2 September 2024 08:23:04 |
| Consumables | Argon gas, welding tips, gas lenses, filler rods |
| Accessories | Foot pedal, welding torch |
| Training requirement | yes |
| Training link | Welding Training |
| ACnode | no |
| Owner | Hackpace |
| Origin | Bought through pledge in Jan 2015 |
| Location | Metalworking shop |
| Maintainers | Tim, Des, Dean, Liam |
Marshall Dynabolt 250 Amp AC/DC Tig Welding Set, used for accurate welding of steel, stainless steel, aluminium and alloys.
This machine requires training and experience in stick and MIG welding techniques before use.
If you want to quickly weld mild steel please consider using the stick welder.
A good intro to welding with aluminium can be found here..
http://www.lincolnelectric.com/en-gb/support/welding-solutions/Pages/aluminum-faqs-detail.aspx
How to assemble to TIG torch with picture is here
http://welders.tokentools.com.au/tig-torch-assembly/
Electrode Thickness, Amperage and Argon Gas Flow Settings can be obtained here
http://www.millerwelds.com/products/gunstorches/tig-torches/helpmechoose/
Filler Materials for aluminium here
http://www.lincolnelectric.com/en-us/support/welding-how-to/Pages/tig-welding-aluminum-detail.aspx
TIG (Tungsten Inert Gas) welding is particularly useful for aluminium, It uses an electrode nozzle with a fixed (should be permanent, but they do wear) tungsten tip where a plasma 'flame' is created (started with a high-voltage / high frequency starter) and used to heat the filler wire and joint. The nozzle allows a flow of inert shield gas around the working area, reducing slag creation and (particularly important with aluminium) oxidation.
The TIG welder is a 'stick' welder - the electrode / nozzle is held in one hand, and the filler wire applied with the other.
Shield gas
For the TIG we use a Pureshield Argon.
Capacity and rating
The Tig welder has a large range
Power is from a 63 amp socket, on the highest setting the Tig could draw more current than this
Controls
File:TIGWelderFrontPanel.JPG
Details on the front panel controls
| Name | Picture | Description | ||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Main On Off Switch | File:TIGWelderOn Off Switch.JPG | Main switch on the welder, remember to turn off the welder as much as possible in-between setting up for welds | ||||||||||||
| DC+ AC DC- selector | File:TIGWelderDC+ AC DC- Switch.JPG | Do not change this setting with the main power switch ON. This selector has three positions that control the mode of the welder
| ||||||||||||
| Working power range selector | File:TIGWelderWorkingPowerRange.JPG | Do not change this setting with the main power switch ON. There are three possible working ranges, low, medium and high. Each has a slightly different range for DC or AC
| ||||||||||||
| Percentage power dial | File:TIGWelderPercentagePowerWithinRange.JPG | Main power control dial, used to fine tune the amp control of the welder. This dial acts as a percentage of the current selected range. | ||||||||||||
| Remote control enable | File:TIGWelderRemoteAmpageControlSwitch KEEPswitchedOFF.JPG | Used to enable remote current control when a foot control is installed. Until we have a remote foot pedal this should be left in the OFF position. | ||||||||||||
| High Frequency control | File:TIGWelderHF OnAtStrike Off Continous Switch.JPG | Controls the high frequency generation of the welder, this switch has three positions and each has a set use.
| ||||||||||||
| Remote trigger enable | File:TIGWelderTorchSwitchEnable TIG-on STICKoff.JPG | This should be left in the ON position. Used to enable the remote trigger, only place in OFF position when doing Arc welding | ||||||||||||
| Gas overrun timer | File:TIGWelderGasOverrunTimer.JPG | Controls how long after arc cut off the gas will run for. Outer scale is tungsten width, inner scale is time in seconds |
Tungsten and collets
We have a selection of the following tungsten tips and collets to fit
| Size | Color band | Grade | Used for | Notes |
|---|---|---|---|---|
| 1.6mm | Red | 2% Thoriated | DCEN Steel | Slightly radioactive! Do not sharpen without wearing a dust mask. |
| 2.4mm | Red | 2% Thoriated | DCEN Steel | Slightly radioactive! Do not sharpen without wearing a dust mask. |
| 1.6mm | White | Zirconaited | AC Aluminium | |
| 2.4mm | White | Zirconaited | AC Aluminium | |
| 1.6mm | Gold | 1.5% Lanthanated | AC or DCEN, All rounder Steel or Aluminium | |
| 2.4mm | Gold | 1.5% Lanthanated | AC or DCEN, All rounded Steel or Aluminium |
Tungsten electrodes come in a a range of different grades/types, each performs differently and have their own uses.
They are marked with a colour band at one end, do not grind this off!
The following was borrowed from here
ZIRCONIATED Tungsten Color Code WHITE or BROWN, are best suited for AC Tig welding applications.
Zirconiated, White, AC Welding applications. Better start up than Pure Tungsten, Balls up well and has a more stable arc than Pure Tungsten. Better current carrying capacity and high resistance to contamination during welding.
LANTHANATED Tungsten Color Code BLACK, GOLD or BLUE, is suitable for AC & DC welding applications.
Lanthanated, Black, AWS Class EWLA-1.5, AC & DC welding applications. Non-Radioactive Good arc characteristics in ac/dc applications. Applications: carbon & stainless steel, nickel alloys and titanium.
CERIATED Tungsten Color Code GREY or ORANGE, are best suited for low amperage DC welding applications.
Ceriated, Grey, An excellent alternative to Thoriated tungsten especially in low amperage welding. Takes 10% less current to start and has a very stable arc.
PURE Tungsten Color Coded GREEN, are best suited for AC Tig welding applications.
Pure Tungsten, Green, AWS Class EWP, AC welding applications. Least expensive of all electrodes. Applications: aluminum and magnesium alloys.
THORIATED Tungsten Color Code RED, YELLOW, MAUVE or ORANGE, is best suited for DC Tig welding applications.
2% Thoriated, Red, AWS Class EWTH-2, DC welding applications. The most common type of electrode used today. Applications: carbon & stainless steel, nickel alloys and titanium.
Grinding tip shapes
Do not grind the end with the color band!
Training
https://wiki.london.hackspace.org.uk/view/Welding_Training
Power supply
A 63A plug and socket connection is used, with a pushbutton on/off control station and no-volt release.
RFID control of access will be installed shortly.
Tig welding tips
Random collection of useful links
- http://www.mig-welding.co.uk/tig-technique.htm
- http://www.millerwelds.com/resources/improving-your-skills/tig/
- http://www.mig-welding.co.uk/tig-calculator.htm
- http://www.gowelding.org/TIG_Welding.html
Risk Assessment - Welding
This risk assessment is intended to provide guidance on the risk associated with the above equipment and activities in normal use. Please also check general risk assessments for the space as a whole. Any discrepancies, errors or concerns should be raised with the document maintainers or trustees - do not edit this assessment directly. For responsible persons and last update, see 'version log' of the assessment page.
Activity
Welding of metals via any electric process (MIG, TIG or MMA/Stick)
Signage
Understanding Risk Rating
LOW - Ensure current control measures are in place and continue with activity
MED - Control measures may be adequate, co-supervision is recommended
HIGH - Do not undertake activity without further consultation with area specialists
Risk Assessment
| Identify Hazards | Who May be Harmed and How | Severity | Control Measures | Likelihood | Risk Rating |
|---|---|---|---|---|---|
| Radiation from light and heat. | Users | High | Operators are competent in the use of the welding equipment. Full welding masks with a full UV and IR light filter are to be worn during all welding work. Welders flash can cause blindness and affect eyesight. Fire retardant gloves are to be worn. Hot material is to be treated with care and watched until sufficiently cool as not to pose a fire risk. All material must be fully secured in place using appropriate clamps to earth before the weld commences. If the equipment is not in satisfactory working order it should not be used. | Medium | Medium |
| Slips Trips and Falls | Users, Bystanders | Medium | Wear shoes or boots with non-slip soles, in particular in wet or snowy weather – make sure excessive wet isn’t tracked into the space. Ensure that good standards of housekeeping are maintained at all times, cables and other equipment will be managed so as not to cause a trip hazard. | Medium | Low |
| The light emitted by the weld can be dangerous to others who look directly at the it. | Bystanders | High | Screens must be put in place to protect others in the area. Welding tools will not be left unattended. The area will be made safe at the end of each session. | Medium | Low |
| Fire from Hot Work | Users, bystanders, public | High | It should be ensured that there is no combustible material in close proximity to the work. Suitable protection should be provided for any combustible items that cannot be moved and for combustible construction such as wooden worktops. A check should be carried out on all of the surrounding areas to minimise the possibility of ignition by heat transfer. Fire extinguishers are be provided in the space. Hot work’ should be stopped at the specified time before leaving the space. A thorough inspection of the area should be undertaken once the work is complete after completion. Where necessary, a further check should be carried out before leaving the space. Welding rods are to be cooled in a water filled bucket before disposal, or placed in a sand bucket, not discarded. | Medium | Medium |
| Use of gas bottles, leaks and high pressure discharge. | Users, bystanders, public | High | Bottles must be secured in the upright position, preferably on a trolley to aid mobility. All gauges, hoses, bagging and torches must be examined before use, any faulty equipment must be repaired or replaced prior to use. | Medium | Low |
