Torches, torch heads, remote controls, trolleys and carry cases for a compact multi-voltage TIG inverter, and how to choose and care for them.
Who should inspect and test the welding set and its accessories?
The welder should carry out daily checks and report any defects. Employers should have a programme of regular checks for welding sets, and leads, plugs, clamps and torch insulation should be undamaged and connectors clean and rated for the current.
There is no single fixed testing interval. How often depends on the type of equipment and where it is used, so a mobile set on site needs checking more often than one in a quiet workshop. Visual examination is an essential part of the process, but some defects can only be found by testing, so a competent person should inspect and test at intervals set by your risk assessment.
Which parts of a TIG torch wear out first?
Most of the small parts at the torch head are consumables. The collet and collet body wear from the tungsten being pushed in and out, and a tungsten that slips even when the back cap is tight often points to a worn collet or collet body. Cups crack or chip, insulators can crack or melt, and back caps and seals suffer from damaged threads.
Look over these parts whenever you change the tungsten. Replace any that are cracked, burnt, stripped or loose rather than carry on, and do not overtighten the back cap, as that can damage the collet body. A damaged collet body can also upset gas coverage.
How do I find a gas leak or a gas problem at the torch?
If the weld looks porous or discoloured, check the whole gas path before turning up the flow. Both too little and too much flow can cause porosity, because excess flow creates turbulence that draws air into the shield, so more gas does not always help.
Look for a cracked gas hose, loose connections at the regulator or torch, a loose collet body or gas lens, a damaged back cap seal, a cracked cup and draughts at the work. Use a suitable leak-detection fluid on joints, never a flame. Set the flow to the torch and cup maker's advice.
Is a gas lens worth fitting instead of a standard collet body?
A gas lens has fine mesh screens that smooth the shielding gas into a steadier, laminar flow. A gas lens improves protection on sensitive joints such as vertical, corner and edge welds, and it often lets the tungsten extend further from the cup, which can help in awkward joints.
The drawbacks are that the screens can clog, the body can be bulkier, and it needs a compatible cup and sometimes a matching insulator. A standard collet body is simpler and works well for general work. Parts are specific to the torch series, so check your torch's parts list to see which options fit.
How do I choose a torch rating to suit a compact inverter?
Look for the torch's rated current and its duty cycle, and compare them with the highest current you actually plan to weld at, not just the machine's maximum output. Duty cycle is the share of a ten-minute period that a torch can carry a stated current, so a 60 percent rating means about six minutes of welding in every ten at that current. Running above the rating risks overheating, and a torch has no automatic cut-out like a machine, so its consumables simply start to burn.
Also check that the connector, gas fitting and control plug suit your machine. The data plate and manual are the starting point, or ask our team.
How do I choose the right cup size and material?
Cups are normally numbered by size, with the middle sizes used for general work, smaller ones for tight joints and larger ones where wider shielding is needed. A larger cup uses more gas, so the flow may need adjusting. The choice depends mainly on electrode diameter and joint access.
Ceramic cups are the usual general-purpose choice and resist cracking well. Clear glass-type cups let you see the weld area and gas coverage, but treat them with care and keep within the maker's current guidance. Cups are specific to the torch series and do not interchange even when they look alike, so match them to the torch and collet body.