Everlast ULTRA-ARC 205, Operator'S Manual

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Section 3 Operation
starts to melt before you dip, you have it too close, or you
have the rod inclined too much so that heat is being di-
rected too far in front of the puddle. As you add the filler
wire, be sure to pause momentarily with the forward travel
of the torch. If desired, a tiny back step motion may be
used to improve weld appearance. There are other ways
to add filler and to create a sound weld. You can keep the
filler wire in the puddle, with the rod laying in a flatter pro-
file and weld. As the torch moves forward and the rod
melts, the filler can be slid, with gentle pressure, into the
puddle as needed to fill the weld. This is known as the
Lay - Wire technique. Another method of welding has more
to do with torch manipulation than it does filler addition, is
called walking the cup. The cup is rested on the metal
while the torch head is oscillated in a figure 8 pattern.
This will require a forehand grip typically, and a good bit of
motion of your forearm/wrist to accomplish. The filler
metal should be moved from side to side to provide an
evenly filled puddle under the Tungsten. This method
requires much practice and effort, but yields beautiful
welds when performed correctly. If you cannot see the
puddle or your helmet flashes (auto darkening types), you
need to change your settings. Practice feeding the filler
wire without actually welding. Manipulating the wire takes
practice and concentration at first. The wire should be
held so that a flicking motion of two fingers and the
thumb can propel the rod forward into the puddle without
loosing grip on the filler rod. The rod should rest on the
two fingers furthest from the thumb, while the index and
middle finger grasp the rod with the thumb propelling it
forward. Other rod manipulation variations may be used,
but the key is to develop a comfortable, natural movement
that is regular and consistent. If feeding difficulty is en-
countered, there are some feeding devices that reduce the
effort to feed the filler wire and smooth out the feeding
process. Do not let feeding the filler wire hold up the
learning process. There are numerous accounts of welders
making home - made jigs or devices that help feed the TIG
rod smoothly. One helpful hint is to make sure you have
gloves that offer protection without compromising dexteri-
ty. With a proper fitting TIG glove, you should be still able
to pick the filler wire up from the table top with your fin-
gers.
There are a lot of hurdles to becoming a proficient TIG
welder. But if you will practice when you are not tired, and
are comfortable in your surroundings, it will help you learn
the art a lot faster than if you are practicing when you are
too tired, or not alert.
Basic TIG Operation
TIG Pulse. The TIG pulse creates two amp values, a high
and a low value that cycle back and forth between each
other while welding. The upper amperage is called the
“ TIG Pulse Amps ” (sometimes referred to as “ Peak ” cur-
rent.) The lower amperage is called “ TIG Pulse Base
Amps “ (sometimes called “ background ” or “ base “ cur-
rent). The number of times this happens per second is
called TIG Pulse Frequency, or Hertz (Hz). Pulse is used
to prevent overheating the metal, particularly on metals
that are prone to structural deterioration or burn through.
It is also used to constrict the arc, improving arc directa-
bility and stability. It can also be used for improving
weld aesthetics and even for timing the addition of filler
to the weld. Regardless of the use or application, in
effect you are creating an average of amps, which will
seem to “ cool ” the puddle.
This welder offers three field proven preset programs
that are typical of how the average user might employ
pulse. However, the pulse frequency (Hz) is adjustable
from .1 to 150Hz to allow the user to fine tune the pro-
grams to meet the demands of application. Lower fre-
quencies up to 2 Hz are typically used to time the filler
“ dips ” into the weld puddle and to create a freeze in the
puddle. This helps form the highly regarded “ stack - of -
dimes ” look that many are looking for. The stack - of -
dimes look is aesthetically pleasing, but not always re-
quired or helpful to the TIG welding process.
An in crease of pulse frequency represents a less fluid
puddle. However, the arc will be pinpointed more as
frequency increases. This is usually used on outside
edges on thin metal, or anywhere heat control or over -
wicking of the weld puddle becomes a concern.
Since the three TIG pulse programs are already preset in
terms of pulse time on and pulse balance, it does simpli-
fy the setup process and allows almost anyone to pick up
the basics of pulse TIG operation. Even so, the user may
have trouble visualizing the performance of the pulse.
The following illustration on the next page give a visual
representation in practical terms of what is happening
during a typical pulse cycle.