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TIG PROCESS
The TIG torch tungsten electrode is the wear and tear
element.
Despite the great performance, it is recommended to avoid
thorium doped electrodes (red strip) for an absolute safety
reasons about pollution, explained down below.
Along the electrode, the electrode holder clamp and the gas
conducting nozzles themselves, also suffer from wear and
tear.
The electrode holder clamp will always be used with the
same diameter as the electrode.
The nozzle will be of the diameter (indicated by its number)
according to the work kind and gas consumption.
The elements are manually easy-disassembled by the plain
threads and knurling systems.
Do not use nor sharpen thorium doped tungsten
electrodes due to the moderate radioactive
activity risk of the material. You will be able to recognize
the thorium dioxide presence and concentration by its
indicative strap on the electrode, according to EN ISO
68848:2004 (colors: yellow, red, purple and orange).
Avoid these electrodes and use substitutes with no
content. For example, lanthanum and cerium derived
electrodes (straps: black, grey, blue, gold) which do not
show radioactive activity.
Prepare the electrode by sharpening its tip on the emery
stone so it will stay as a cone with an approximated height
of twice the electrode diameter. For a better arc and current
managing capacity, the proper attack from the tip to the stone
must be longitudinal, and the tip should be slightly flat.
MIG/MAG PROCESS
The torch contact tip is the main tear and wear element in
this process, that must always be replaced according to the
continuous wire diameter that is being used. The torch nozzle
will also suffer tear and wear due to the high temperatures and
projections. The elements are manually easy-disassembled
by the plain wide passage threads systems. For an aluminium
special welding, please contact your supplier for the inner
conduct replacement (liner) to low-friction Teflon.
The mechanism of the winder has a simple operation of
the grooved rollers replacement. It is manually done by the
threaded knob that releases the pulleys, whose position can
be reversed in order to select the complementary diameter
(For ex. 0.8mm at one side and 1mm at the other). Note: be
careful not to lose the cotter pin of the winder when releasing
the pulley.
The welding wire is received on its coil and installed by
introducing it inside the winder exe and leading it to the torch
output through the traction pulleys, torch hose and torch
contact tip. The contact tip is accessible by manually twisting
the torch nozzle.
The contact tip may be removed with an open-end wrench or
pliers and must be of the same diameter as the welding wire.
Pulleys are accessible by freeing the pressure bearings that
release them. Once the wire goes through the pulleys, should
you close the pressure rollers and adjust pressure so the wire
can correctly advance and not skid nor end up destroyed.
The pulley groove must be of the same diameter as the
welding wire.
When using hollow wire, the nozzle can be removed as it is
not necessary. By doing that, you will have a wider vision and
the nozzle will not get damaged.
SETTING OPERATIONS
MMA PROCESS (COATED ELECTRODE)
Stayer offers high-quality coated electrode in the references
down below. For all the models, use as a first approximation,
the
following
Ref. STAYER
MODEL
38.93
E6013
38.94
E6013
38.99
E6013
38.100
E6013
38.96
E7018
38.102
E7018
For higher than a 3.25mm diameter, refer to the intensities recommended by your
supplier.
TIG PROCESS
For all the models, use as a first approximation the amperage
and gas flow adjustment in the following table (steel in
general):
Workpiece thickness
Tungsten electrode
mm
0.6
1.0
1.5
2.5
3.0
4.0
5.0
6.0
8.0
12.0
Amperage adjustment
range
A
15 - 30
25 - 30
50 - 70
65 - 95
65 - 95
110 - 150
120 - 180
150 - 200
160 - 220
180 - 240
180 - 240
MIG/MAG PROCESS
For all the models, use the following table as a first
approximation for the adjustment with carbon steel. The wire
speed will variate depending on the piece thickness and the
required welding mode.
Diameter (mm)
Amperages (A)
0.6
0.8
50 - 100
1.0
60 - 120
1.2
120 - 250
1.6
200 - 500
-
30
-
amperage
adjustment
DIAMETER
AMPERES (A)
2.5
60-100
3.25
90-140
2.5
60-100
3.25
90-140
3.25
110-150
3.25
110-150
Filler rod diameter
diameter
mm
mm
1.0 - 1.6
0 - 1.0
1.0 - 1.6
0 - 1.6
1.0 - 1.6
0 - 1.6
1.6 - 2.4
1.6 - 2.4
1.6 - 2.4
1.6 - 2.4
2.4
1.6 - 2.4
2.4 - 3.2
2.4 - 3.2
2.4 - 3.2
2.4 - 3.2
3.2 - 4.0
3.2 - 4.0
3.2 - 4.0
3.2 - 4.0
Argon gas flow
Joint size
L/min
mm
4 - 5
1
4 - 7
1
6 - 9
1
6 - 9
1
6 - 9
1
10 - 15
2 - 3
10 - 15
2 - 3
10 - 15
2 - 3
12 - 18
4 - 5
12 - 18
6 - 8
12 - 18
6 - 8
Voltage (V)
Gas flow (L/min)
40 - 80
14 - 20
6 - 10
15 - 21
7 - 12
16 - 22
8 - 12
22 - 28
12 - 14
25 - 32
14 - 16
table:
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