Decision -- Do I get the Miller Diversion 180 or the Lincoln Square Wave 200

[Auto_Tech]

Here's the comparison:

			Lincoln Square Wave 200			Miller Diversion 180
			$1,399.00			$2,075.00
INPUT			120/230/1/50/60			120/230/1/50/60
OUTPUT
120V:	21A	110A/25%)
					26.5A	125A/35%
		17A	100A/40%
	14A	85A/60%
					11.3A	60A/100%
	230V:
		22A	200A/25%
					20A	180A/15%
		17A	160A/40%
					16A	150A/20%
		13A	130A/60%
					5.6A	60A/100%
DIMENSIONS (H X W X D)			14.0 in x 10.75 in x 19.25 in			17.0 in x 9.875 in x 23.875 in
NET WEIGHT			46.5			50
AC FREQUENCY			60-150 HZ			Preset
AC BALANCE			60-90%			Preset
AC PULSE			0.1 - 20 PPS			Preset
POST FLOW
WARRANTY			Three Years			One Year

I plan on using the TIG to do aluminum repairs on various automotive engine blocks, components and transmissions. Price strongly favors the Lincoln. Miller has a duty cycle advantage at 110V, Lincoln has a duty cycle advantage at 230V. I noticed that the Miller uses "presets" on its AC Frequency, Balance and Pulse --isn't that a problem limiting flexibility?

My budget is $1500-$2500 tops.

[aametalmaster]

I sell them both as well as a few others. My vote is the Miller...Bob

[H80N]

...I plan on using the TIG to do aluminum repairs on various automotive engine blocks, components and transmissions.....

....My budget is $1500-$2500 tops.

I would submit that NEITHER one of those machines have the horsepower or duty cycle to effectively TIG weld those heavy aluminum castings.... Even with a Helium mix & preheat....

AND... your budget is low for a proper new machine

If I were you I would look for a used machine like the Syncrowave 250-350 class....

that would match your needs and budget

[aametalmaster]

For sure aluminum takes some power. Me being hooked on alum welding with a spool gun for the last 39 years i am lost for what TIG to get...Bob

[shovelon]

Well I just bought two Lincoln SW200s if that means anything. The optional 2 years of warranty that cost me an extra $140 gets me a solid 5 years warranty. Rock solid and stupid simple but comes with some quality accessories like the copper contact ground clamp, Lincoln's version of flextorch which I have not been able to burn up yet, Smith dead on accurate flowgauge and high quality semi rigid gas hose for gas economy, and American made SCC controls foot pedal. I did put a heel clip on one already and is so nice.

The pulse is stupid, and the capacitor discharge pop start is 25 amps, so alum soda cans are tough to start without starting your arc lay rod style on the filler, but it is doable. Has no pre or postflow adjustments but has not concerned me. I went this route to back up my Dynastys for field work that can plug into house current. So far no regrets.

[H80N]

Well I just bought two Lincoln SW200s if that means anything. The optional 2 years of warranty that cost me an extra $140 gets me a solid 5 years warranty. Rock solid and stupid simple but comes with some quality accessories like the copper contact ground clamp, Lincoln's version of flextorch which I have not been able to burn up yet, Smith dead on accurate flowgauge and high quality semi rigid gas hose for gas economy, and American made SCC controls foot pedal. I did put a heel clip on one already and is so nice.

The pulse is stupid, and the capacitor discharge pop start is 25 amps, so alum soda cans are tough to start without starting your arc lay rod style on the filler, but it is doable. Has no pre or postflow adjustments but has not concerned me. I went this route to back up my Dynastys for field work that can plug into house current. So far no regrets.

Terry

am REALLY curious to see how they perform & hold up in the long run...........

PLS keep us posted.....

[ryanjones2150]

I agree with H80N, neither of those machines are good choices for welding on engine blocks, heads or transmission housings. Cast aluminum is tough to weld, you need adjustability and power. Lots of power to weld aluminum. <br />
<br />
I also think you will out grow those machines very quick. You'd be money ahead of you moved straight into a higher end machine, even if it's a used one. I speak from experience. My first aluminum tig machine was a "frankenwelder" scratch start from a high freq box and a thunderbolt. Then I moved into a basic tig machine and was ready for something bigger and better within the first month. I wasted A LOT of money doing it the hard way.

[Andyman1]

Auto_Tech,

Check this out-

https://www.youtube.com/watch?v=Mg91XxNFYts

Make your own decision. Put some cash back in your pocket.

[Auto_Tech]

I would submit that NEITHER one of those machines have the horsepower or duty cycle to effectively TIG weld those heavy aluminum castings.... Even with a Helium mix & preheat....

AND... your budget is low for a proper new machine

If I were you I would look for a used machine like the Syncrowave 250-350 class....

that would match your needs and budget

Thank you --- they're most impressive but just way beyond my small budget. I sure wish I could afford them but for a small shop (me and two other part time auto techs) that's pretty big money.

I thought I could just multi-pass the TIG over small to medium cracks in aluminum bell housings (for example). Needed the penetration vs cleaning settings since I'm dealing with cast alum that typically has oil, trans fluid residuals. I'm a slightly better than average MIG welder and have tried MIG (and also Oxy/A) on cast aluminum ----it's IMPOSSIBLE because of the (hidden) aluminum oxides and residual automotive fluids. I know why MIG failed, but I'm not sure about Oxy/A --- possible a flux issue, not sure.

[Auto_Tech]

Auto_Tech,

Check this out-

https://www.youtube.com/watch?v=Mg91XxNFYts

Make your own decision. Put some cash back in your pocket.

Wow Jody can lay down some stacked dimes --- awesome.

[aametalmaster]

I thought I could just multi-pass the TIG over small to medium cracks in aluminum bell housings (for example). Needed the penetration vs cleaning settings since I'm dealing with cast alum that typically has oil, trans fluid residuals. I'm a slightly better than average MIG welder and have tried MIG (and also Oxy/A) on cast aluminum ----it's IMPOSSIBLE because of the (hidden) aluminum oxides and residual automotive fluids. I know why MIG failed,

Let me tell you about welding auto castings as i have done them with a MIG for the last 39 years. 99% can't be welded in one perfect pass. One reason which you said is oil. Sometimes i grind, weld, grind and weld again until you get a clean, solid weld. You just have to. I also weld aluminum wheels which have rubber, dirt and sometimes JB Weld in the crack. So a perfect weld is required there to hold air plus the strength of the wheel...Bob

[shovelon]

Terry

am REALLY curious to see how they perform & hold up in the long run...........

PLS keep us posted.....

That is why I opted for 5 years warranty Heiti. I have mine over at a vacuum chamber test lab this morning doing some upgrades to the interior of one. Never fails to start an arc, and pedal range is excellent. I may invest in a CK belted finger control like I have on my Dynasty in another couple of months. The engineers were ogling over it when I plugged into 115volt outlet. Still though not as versatile as my 200DX. Wish it had a better pulse.

[H80N]

That is why I opted for 5 years warranty Heiti. I have mine over at a vacuum chamber test lab this morning doing some upgrades to the interior of one. Never fails to start an arc, and pedal range is excellent. I may invest in a CK belted finger control like I have on my Dynasty in another couple of months. The engineers were ogling over it when I plugged into 115volt outlet. Still though not as versatile as my 200DX. Wish it had a better pulse.

a vacuum/high altitude chamber will certainly help highlight weak insulation in the HV sections....

Used to prep CRT displays for our non pressurized high altitude flights

you would be amazed at how much flyback corona we had to suppress with copious amounts of glyptol....

otherwise the crt electronics would self destruct at about 20K feet alt (pretty spectacular show... catastrophic fail)

[H80N]

Thank you --- they're most impressive but just way beyond my small budget. I sure wish I could afford them but for a small shop (me and two other part time auto techs) that's pretty big money.

I thought I could just multi-pass the TIG over small to medium cracks in aluminum bell housings (for example). Needed the penetration vs cleaning settings since I'm dealing with cast alum that typically has oil, trans fluid residuals. I'm a slightly better than average MIG welder and have tried MIG (and also Oxy/A) on cast aluminum ----it's IMPOSSIBLE because of the (hidden) aluminum oxides and residual automotive fluids. I know why MIG failed, but I'm not sure about Oxy/A --- possible a flux issue, not sure.

There are plenty of used machines in the Syncrowave 250-350 class out there within your budget range

Where in the country are you located..??

[Auto_Tech]

There are plenty of used machines in the Syncrowave 250-350 class out there within your budget range

Where in the country are you located..??

I'm near Richmond, VA and definitely looking at used Syncrowaves now --- just looked at a lightly used 210 Multi-process --- a step up from where I was originally looking. AirGas Outlet has this new 200 too (not quite the 250-350 class however):

http://airgasoutlet.com/products/mil...fully-equipped