Cold Wire Tig

[GaryM]

Has anyone used a Cold wire tig set up?

Gary

[HAWK]

GaryM,

The only cold wire TIG set ups I have seen are probably antiquated by set ups of today. Most of what I am telling you refers to the 1970's error. Some of the differences in cold and hot wire TIG process are: deposition rate, travel speed, and welding time.

In cold wire TIG the filler is fed under the arc (in a machine type torch set up) by a semi automatic feeder similar to a MIG feeder. If the wire is fed too fast cold lap will occur. The reason is the heat of the arc is taken up by the cold wire. Many cold wire feed assemblies tend to block of the view of the actual arc. This can be aggravating. I like to see what I am welding.

Hot wire TIG is a better process as the wire is preheated before entering the torch area. The set up does not utilize the arc heat to preheat the filler wire and prevents cold lapping that can occur with the cold wire process. The heat of the arc can be directed at fusing the base metals. Hot wire TIG is not used much for aluminum or copper. These wires have a low resistance and don't do well well with the hot wire process.

Here are some comparison numbers from Linde Division of Union Carbide. As I said this old information. Deposition rate for cold wire is 3 pounds/ hour and 11 pounds/ hour for hot wire TIG process. Travel speed is 8 inches/minute for cold wire TIG compared to 12 inches/minute in the hot wire TIG process. Welding time for the cold wire TIG process is 14 minutes per foot of weld while hot wire TIG can yield the same foot of weld in 5 minutes.

I THINK IF YOU ARE SERIOUSLY CONSIDERING EITHER OF THE PROCESSES, A BETTER CHOICE WOULD BE THE VARIABLE POLARITY PLASMA ARC PROCESS. By today's standards it is a perfect procedure in wide range of applications where standard GTAW falls short.

Good luck with your search. Exactly what are you trying to accomplish by any of these processes?

[GaryM]

I am looking at seting up a tube/pipe welding automation system i weld alot of alumunum diesel fuel tanks. I spent 7 hours cutting and welding on two tanks yesterday(they had to be shortened by 8") i think if i had a setup that
i could set up a plasme and a cold wire tig system i could cut the weld time maybe down to 2 hours a tank.

Today i need to make 2 welds on tanks. that is going to take a while.

If I am going to go that far would like to make it able to weld steel,stainless steel and other alloys.

Just looking at makeing more use of my time. Remeber time is money!!!!!


Gary

[HAWK]

GaryM,

Sounds like nice project. If it is ongoing and you can borrow the cash, a variable polarity plasma arc welder is the ticket! You can increase your travel speeds and penetration while decreasing your weld amperage. Price for such equipment ranges from 45K-75K depending on brand and accessories. Liburdi has a great basic unit in the mid 40's and the newest of update of the NASA machine will be out soon near 80K.

Drop an email to GTA/SPEC on this forum. He is very knowledgable of the VPPAW process and equipment! If you want, I can email you the info he has already sent me as I am considering VPPAW. What is you email?

[GaryM]

Well i think that maybe way out of my leage right now maybe later. I would have to be making a thousand a day to pay for something like that. Now if i could aford to have someone market the welding for me i would look at it. I dont so no worries about buying anything like that.

Also I would love to get the info you have on the Liburdi.

Gary

[HAWK]

GaryM,

I am unable to email via the forum. Drop me a note at [email protected] for an address to send to. I will send you that as well as other good info from GTA/SPEC pertaining to plasma arc welding


The marketing issue can be addressed by mailers, cards, emails, etc. This could work out to be much less than a marketing firm.

[GTA/SPEC]

Gary,

Cold wire is an excellent tool to use for semi-auto or fully-auto production. The last time i used mine, was in a semi-auto situation welding 5" x 36" aluminum air filters of some sort. The tube was 093 wall, 5 inches in diameter and the end caps were .75" thick, machined to insert into the tube, and had a bevel. I used my positioner, an older cold wire unit, and a Maxstar 200 set at 150 amps, with pure helium. I could have a part loaded, welded and unloaded in 45 seconds. It was a good job.

I know that 45k sounds like alot for a welding machine, but it can also control a positioner, wire feeder, torch osc, and AVC (arc length). It would give you infinate control over the the other motion requirements. You could use it with a weld lathe, weld head (for tubing), pipe head, or for linear motion. You really get more than just a quality welding machine.

[HAWK]

GTA/SPEC,

Thanks for the input.