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WELDING INDUSTRIES MALAYSIA SDN. BHD.

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1
NAME OF PROCESS

GTAW - Gas Tungsten Arc Welding


TIG - Tungsten Inert Gas
- Argon

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FEB - 07 | Witc/PRODUCT TRAINING/HZ
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3
PRINCIPAL OF GTAW WELDING

1. Utilize the heat of an arc between


a non consumable tungsten
electrode and base metal.
2. Filler metal is not added if the
material is thin. For thick material
filler rod is used.
3. Filler metal is not transfer across
the arc but melted by it.
4. The arc is protect by inert
shielding gas. Witch flow by the
nozzle.
5. The result weld is smooth and
uniform and requires minimum
finishing.

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TYPE OF TIG WELDING PROCESS

•Two types of current


•DC type • AC type

o Mild steel – Aluminum


o Stainless steel
o Copper
o Brass
o Alloy steel
o Titanium
o Tungsten

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TIG PROCESS

• AC TIG – Alternating / Alternative current, is needed to


remove the oxide layer from the aluminum base metal
and filler metal.
• DC TIG – welding of aluminum by (-) polarity and with
Argon shielding gas is impossible, oxide has too high
melting point.
• Aluminum base material is having low melting point.
• DC TIG arc is not having enough to break oxide or
remove it.
• DC TIG arc can melt aluminum base material but not
fuse two sides together because of oxide skin in root
faces.

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6
ADVANTAGE OF TIG

• It will make high-quality welds in almost all metals


and alloys.
• Very little, if any, post weld cleaning is required.
• Pin Point Control.
• The arc and weld pool are clearly visible to the
welder.
• No Sparks or Spatter.
• Welding can be performed in all positions.
• No Flux or Slag.
• No Smoke or Fumes.

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DISADVANTAGES OF TIG

• Slower travel speeds than other processes.


• Lower filler metal depositions rates.
• Hand-eye coordination is a required skill.
• Brighter UV rays than other processes.
• Equipment costs can be higher than other
processes.

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ADVANTAGE OF TIG

BASE METAL WELD ABILITY


Aluminums Weld able
Bronzes Weld able
Copper Weld able
Copper nickel Weld able
Cast iron, malleable, nodular Possible but not popular
Wrought iron Possible but not popular
Lead Possible
Magnesium Weld able
Inconel Weld able
Nickel Weld able
Monel Weld able
Precious metals Weld able
Low-carbon steel Weld able
Low-alloy steel Weld able
High-and medium carbon steel Weld able
Alloy steel Weld able
Stainless steel Weld able
Tool steel Weld able
Titanium Weld able
Tungsten Possible
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TYPE OF TUNGSTEN

AWS APPROXIMATE COLOR


CLASSIFICATION COMPOSITION CODE

EWP Pure tungsten Green

EWCe-2 97.3% Tungsten, 2% cerium oxide Orange

EWLa-1 98.3% Tungsten, 1% lanthanum oxide Black

EWTh-1 98.3% Tungsten, 1% thorium oxide Yellow

EWTh-2 97.3% Tungsten, 2% thorium oxide Red

EWZr-1 99.1% Tungsten, zirconium oxide Brown

EWG 94.5% Tungsten, remainder not specified Grey

WL 15 98.5% Tungsten, 1.5% lanthanum Gold

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TYPE OF CURRENT FOR TUNGSTEN

Tungsten DCEN DCEP Alternating-current Alternating-current

electrode diameter Unbalanced wave Balanced wave

mm EWX-X EWX-X EWP EWX-X EWP EWX-X

1.60 70-150 50-100 70-150 30-80 60-120

2.40 150-250 15-30 100-160 140-235 60-130 100-180

3.20 250-400 25-40 150-200 225-325 100-180 160-250

4.00 400-500 40-55 200-275 300-400 160-240 200-320

5.00 500-750 55-80 250-350 400-500 190-300 290-390

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11
WHAT IS THE CORRECT WAY TO GRIND A TUNGSTEN?

CORRECT (√) WRONG ( x)

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WHAT IS THE CORRECT WAY TO GRIND A TUNGSTEN?

Correct way to holding tungsten

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13
RECOMMENDED FILLER METAL

Base Material Electrode Clasification


Type Classification
Carbon Steel Hot and cool rooled E70S-3, E70S-2, E70S-4
plain carbon steels E70S-5, E70S-6
Austenitic Stainless Type 201 ER308
steel (ASTM standard 301, 302, 304, 308
volume 1.04) Type 308L ER308L
Type 310 ER301
Type 316 ER316
Type 321 ER321
Type 347 ER347
Aluminum and Aluminum 1100 ER4043
alloys (ASTM Standard 3003, 3004 ER5356
volume 2.02) 5052, 5454 ER5554, ER5556 or ER5183
5083, 5086, 5456 ER5556 or ER5356
6061, 6063 ER4043 or ER5356

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RECOMMENDED FILLER METAL

Base Material Electrode Clasification


Type Classification
Copper and coper alloys Commercially pure Ercu
(ASTM standard voleume 2.01) Brass ERCusi-A, ERCuSn-A
Cu-Ni alloys ERCnNi
Manganese bronze ERCuA1-A2
Aluminum bronze ERCuA1-A2
Bronze ERCuSn-A
Magnesium alloys AZ10A,
(ASTM standard AZ31B, AZ16A ERAZ16A, ERZA92A
Voleume 2.02) AZ80A, ZE10A ERZA61A, ERZA92A
AZ63A, AZ81A, AZ91C EREZ33A
AZ92A, AM100A,
HK31A, HM21A EREZ33A
HM31A, LA141A EREZ33A

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15
RECOMMENDED FILLER METAL

Base Material Electrode Clasification


Type Classification
Nickel and Nickel alloys Commercially pure ERNi
(ASTM standard Ni-Cu alloys ErRNiCu-7
voleume 2.04) Ni-Cr-Fe ERNiCrFe-5
Titanium and titanium Commercially pure ERTi-1, -2, -3, -4
alloys (ASTM standard Ti-5A1-4-4V ERTi-6A1-4V
voleume 2.04) Ti-0.15pd ERTi-0.2pd
Ti-5A1-2.5sn ERTi-5A1-2.5sn
Ti-13V-11 Cr-3AL ERTi-13V-11 Cr-3AL

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16
SHIELDING GAS

• TIG Shielding
– Argon
– Helium
– Argon / Helium Mixture
– Argon / Hydrogen
– Argon / Nitrogen

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SHIELDING GAS comparison

• ARGON HELIUM
– Good Arc Starting – Faster Travel Speeds
– Good Cleaning Action – Increased Penetration
– Good Arc Stability – Difficult Arc Starting
– Focused Arc Cone – Less Cleaning Action
– Lower Arc Voltages – Less Low Amp Stability
– 10 – 30 CFH flow rates – Flared Arc Cone
– Higher Arc Voltages
– Higher Flow Rates (2X)
– Higher Cost then Argon

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SHIELDING GAS

• ARGON / HELIUM Mixes


– Improved travel speed over 100% Argon
– Improved penetration over 100% Argon
– Cleaning properties closer to Argon
– Improved arc starting over 100% Helium
– Improved arc stability over 100% Helium
– Arc cone shape more focused than w/ Helium
– Arc voltage between pure Argon and Helium
– Higher flow rates than Argon
– Costs higher than Argon

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19
APPLICATION OF TIG WELDING PROCESS

Fields of application :
Automotive and Accessories
Home and Kitchen Application
Industrial
Medical
Office equipment
Tools and Janitorial
General

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TYPE OF WELDING PROCESS

• GTAW
HF / Scratch ARC

– Thyristor DC
– Thyristor AC/DC
– Inverter DC
– Inverter AC/DC

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21
WIM MODEL MACHINE

HIGH FRUQUENCY
•Thyristor AC/DC
• Thyristor DC

TG 160 TG 301P AC/DC


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22
WIM MODEL MACHINE

SCRATCH ARC
• Thyristor DC
•Rheostat

TS 300 - 600 RS 500


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23
WIM MODEL MACHINE (inverter)

HIGH FRUQUENCY
•Inverter DC
•Inverter AC/DC

ITG 202P ITG 180 A ITG 300/500 P AC/DC

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24
WIM MODEL MACHINE (inverter)

SCRATCH ARC
•Inverter DC

ES1600
ES1200

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25
TG 160 SPECIFICATION

HIGH FRUQUENCY
•Thyristor DC
Model: TG 160

Input 220/240V
Voltage: 1 Phase

Duty Cycle: 20%

Type H/F DC

Cooler Air cooled

Amps: 8 - 160

Weight 62 Kg

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26
PRODUCT FEATURES

Process
selector

Current
adjuster
Crater
selector

Crater current &


gas post flow Terminal
output

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27
PRODUCT FEATURES

Features

• Single range current control form 160amps


down to 8 amps.
• Easy to operate
• Crater current

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28
TG 301P SPECIFICATION

HIGH FRUQUENCY
•Thyristor AC/DC
Model: TG 301P
Input 380 / 415 V
Voltage: 2 Phase

Duty Cycle: 50%

Type H/F AC/DC

Cooler water cooled

Amps: 20 - 300

Weight 175 Kg

TG 301P AC/DC
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29
PRODUCT FEATURES

Analog
display On off
switch

Operation All weather


panel protection for field
construction

Terminal
out put

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30
PRODUCT FEATURES

Features

• Automatically adjust AC wave balance.


• Excellent arc starting and stability for smooth.
• Pulse adjustment of frequency.
• Thyristor output ensures high resistance to AC arc
rectification for best operation when welding aluminum.

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31
RS 500 SPECIFICATION

SCRATCH ARC
• Rheostat DC Model: RS 500

Input 380 / 415V


Voltage: 3 Phase

Duty 60% 400 amp


Cycle:
Type Rheostat

Cooler Air cooled

Amps: 45 - 450

Weight 350 Kg

RS 500
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32
PRODUCT FEATURES

On switch

Fan cooled for


extra thermal
Current protection
adjuster

Wheel

Terminal
output
Terminal out put
Low range and
high range

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33
PRODUCT FEATURES

Features

• Consistence arc.
• Easy to set calibrated output knob.
• Traditional design for demanding industrial environment.
• All weather protection for field construction
• Fan cooled for extra thermal protection.

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34
TS 300,400,600 SPECIFICATION

SCRATCH ARC
• Thyristor DC
Model: TS 300 TS 400 TS 600

Input 415V 415V 415V


Voltage: 3 phase 3 phase 3 phase
Duty Cycle: 60% 60% 60%
Type Thyristor Thyristor Thyristor
Cooler Air cooled

Amps: 30 - 300 40 – 400 50 - 600

Weight 85 Kg 164 Kg 180 Kg

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35
PRODUCT FEATURES

On switch
Current
adjuster Fan cooled for
extra thermal
protection

Selector
function Wheel

Terminal
output
Terminal out put

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36
PRODUCT FEATURES

Features

• Consistence arc.
• Easy to set calibrated output knob.
• Traditional design for demanding industrial environment.
• All weather protection for field construction
• Fan cooled for extra thermal protection.

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37
ES1200 AND ES1600 SPECIFICATION

SCRATCH ARC
•Inverter DC Model: ES1200 ES1600

Input 220/230V 220/230V


Voltage: (1 PH) (1 PH)
5,5KVA 5,5KVA
Duty 60% 60%
Cycle:
Rated 120A 160A
Amps:
Weight 6.8 kg 8 kg
ES1200 ES1600
Electrode 2 – 2.6 2 – 3.2
diameter mm mm
Tungsten 1.6 1.6 – 2.4

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38
NEW PRODUCT FEATURES ES1200 and ES1600

INTERNAL STRUCTURE OF TA350i


Warning Lamp

Welding Current
Adjustment

Power Switch

( - ) Output Terminal for


( + ) Output Terminal
Earth Clamp
for Electrode Holder

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39
INTERNAL STRUCTURE DESCRIPTION

DRIVER BOARD

INVERTER
CONTROL BOARD
POWER BOARD

RECTIFIER
BOARD

SINGLE PHASE
POWER SUPPLY,
220V
WELDING
OUTPUT
DC POWER
SUPPLY BOARD
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COOLING SYSTEM DESIGN CONCEPT

The most Extract the most heat


THERMOSTAT heated part
component in one time.
Hot Air Out
If system exceeded
Cool Air
limit, thermostat switched
on to protect the system.

In the meantime, fan


blower maintain extract
hot air out until system
itself back to normal
The most temperature.
heated part
Then system will restart
again.
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41
INTRODUCTION OF ES 1200 AND ES 1600

Features:
1. Portable
2. Compact light
3. Energy saving (40% less power
consumption)
4. Easy control / User friendly CC made
5. Scratch TIG available

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42
ITG 202P SPECIFICATION

HIGH FRUQUENCY
•Inverter DC Model: ITG 202P

Input 230V
Voltage: 1 Phase
Output 18V
Voltage:
Duty Cycle: 40%

Type H/F DC

Cooler Air cooled

Amps: 5 - 200

Weight 15.3 Kg
ITG 202P

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43
PRODUCT FEATURES
Welding ampere
Warning lamp adjustment

TIG & MMA


Selection Pulse high / low

Start and
crater current Gas post flow
timing

Terminal
Terminal
output torch
output work

Torch witch Receptacles


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44
INTRODUCTION OF ITG 202P

Features:
1. Portable
2. Compact light
3. Easy control / user friendly CC mode
4. Energy saving
5. High frequency start arc
6. MMA welding available
7. Pulse dc and excellent low arc performance

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ITG 180A SPECIFICATION

HIGH FRUQUENCY
•Inverter DC

Power Source ITG 180A


Rated Input Voltage 220V / 1 PH (+/- 10%)
Rated Input (KVA) 6.6
Duty Cycle 60% 180A
Output Current (A) 5 ~ 180 A
Output Voltage (V) 17
Weight (KG) 8

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46
NEW PRODUCT FEATURES ITG180 A

Warning Lamp Welding ampere


adjustment
TIG & MMA
Selection

Power On/Off

Gas post flow


timing
Work Connector

Torch
Connector

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Torch witch Receptacles
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47
Benefit and Why?

• Low power consumption (3 – 6.6 KVA)


• TG 160 = 11.4 KVA
• Good welding range between 5 – 180 Amps
• Energy saving of 40% compare to
conventional TIG machines
• Clear and clean appearances
• Make quick change between TIG and MMA
welding
• Small and portabl1 year Warranty
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FEATURES OF ITG 180A

Features:
1. Portable
2. Compact light
3. Easy control / user friendly CC mode
4. Energy saving
5. High frequency start arc
6. Post flow gas 3s ~ 8s
7. MMA welding available
8. Over current & thermal protection with warning
indicator
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EVOLUTION OF WELDING

•Arc Welding Process

•Welding Power Technology

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THE “ 3 IN 1 “

+ +

New
=

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51
NEW MACHINE DEVELOPMENT

EVO500
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52
INTRODUCTION OF EVO 500

Features:
1. Digital Amp and Volt display meter
2. Better welding parameters 0.6mm – 1.6mm
3. Thermal protection for power components
4. Inductance control for MIG welding
5. Arc Force control for MMA welding
6. CC and CV mode selection
7. Circuit breaker protection
8. Excellent electronic control for CC/CV welding process
9. Compact due to smaller power components compare to conventional
power source
10. Energonomic and Value added features
11. Energy efficient with high power and low input KVA demand. If powered
by generator, fuel consumption is low compare to conventional machine

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53
EVO 500 SPECIFICATION

Model: EVO 500


Input Voltage: 380/415V (3 PH)
21.5KVA
Type: Scratch / H/F

Duty Cycle: 70%

Amps: MMA, MIG 40-500


Amps: TIG 5 - 500
Weight 73.5 kg

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54
PRODUCT FEATURES OF EVO 500

Welding mode selector Voltage / amp


This multi process switch has control
four positions switch
MMA,TIG,MIG and CV.

Arc Force control


Inductance control for MMA welding
for MIG welding

Digital Amp and Volt


Wheel. Easy to move around display meter

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FUNCTION MACHINE EVO 500

Welding mode selector


1. This multi process
switch has four positions
switch MMA,TIG,MIG
and CV.
2. MMA and TIG modes
are constant current
characteristics.
3. MIG and CV modes are
constants voltages
characteristics.

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INTERNAL STRUCTURE FOR EVO 500

High power fan

40 – 500 AMP

1.2 – 1.6 wire

6013 & 7018

Low input KVA

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EVO500 ACCESSORIES

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EVO500 ACCESSORIES

Accessories needed for TIG process

Valve
type

+ +
WCS 33

Earth Water cool


clam type
Argon regulator

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ITG 300/500P AC/DC SPECIFICATION

HIGH FRUQUENCY
•Inverter AC/DC Model: ITG 300P ITG 500P
AC/DC AC/DC

Input 415 V 415 V


Voltage: 3 Phase 3 Phase

Duty Cycle: 50 % 40 %

Type Inverter Inverter


Cooler Air cooled & water cooler

Amps: 4 - 300 4 - 500

ITG 300P/500P AC/DC 54 kg 62 Kg


Weight

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MACHINE FEACTURES

Pulse adjuster
current On off switch

Digital Panel
amp meter operation

Handle
Terminal
output

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FUNCTION MACHINE

Welding mode selector


1. Selection of TIG function
and Stick (MMA)
function
2. TIG function is
categorize to “Normal”,
“Crater” or “Repeat”
welding process
3. At anytime during
welding only one
function can be selected

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HOW THE MACHINE OPERATED ?

Base Current Pulse Current


Start
Up slope Down slope Crater
current
current
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FUNCTION MACHINE

Start Current Start Current


The function can only be used
on the crater or repeat function.
It is to initiate the starting current
for each process.

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FUNCTION MACHINE

Up Slope Control
Up slope
This knob controls the duration of
time needed for the starting current
to change to the base current.

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FUNCTION MACHINE

Base Current
Welding Base current
This control knob is applied to
welding base current.

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FUNCTION MACHINE

Pulse Current
Pulse current
This knob controls pulse peak current.
This application will help control welding
penetration and heat effect zone by this
function.
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FUNCTION MACHINE

Down slope Down Slope Control

This knob controls the duration of time needed


for the base current to change to the crater
current. It is able to prevent welding defect
happened by high welding current when
finishing welding.

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FUNCTION MACHINE

Crater Current
Crater current
Crater current is used to end section of
welding process. This function is used
to realized perfect performance of
welding bead.

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FUNCTION MACHINE

Gas Post Flow


•It controls the innert gas after the weld
•Advantages:
•To cool the torch
•To cool the tungsten
•To cool the molted weld pool
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FUNCTION MACHINE

Pulse Frequency Function


There are 3 different process for the function:
1. Low pulse frequency (0.5 – 15 Hz) (UP)
2. Off (Normal function) (MIDDLE)
3. Middle pulse frequency (16 – 500 Hz) (DOWN)
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FUNCTION MACHINE

Controlled AC-TIG “Pulse


Width Balance”
• Balance value changes
automatically according to the set
value of the current and selected
form of electrode head
•Advantages:
•Ensure optimum balance
setting for whole current
range
•Same electrode diameter is
use for wider current range
•Same electrode type (grey)
is suitable for both AC and
DC- welding
•Less changes in electrode
diameter and TIG
consumable
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FUNCTION MACHINE

Pulse Frequency
• Has 2 available selection
of frequency “low” and
“medium”
•Low = 0.5 – 15 Hz
•Medium = 16 – 500
Hz
•Advantages:
•Ensure optimum
penetration during
welding process
•Better control during
thin plate welding
process
•Less heat transfer on
work piece

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FUNCTION MACHINE

Cleaning Control
This knob is to control the welding bead cleaning width.
Through this knob, the welding cleaning width could be
controlled and provide the most proper welding condition
an the most suitable welding bead.

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FUNCTION MACHINE

Gas Check Function


-When “Gas Check” position is selected, the welding gas will flowed through the torch without
triggering the welding torch.
-When “Normal” position is selected, the gas flow will be control by triggering the welding
torch

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FUNCTION MACHINE

Water or Air cool


•Selection of water cool will be use when a water cool torch is being used:
*When selecting the water cool function a “Water Cooling System” (WCS 33) will
be needed for this operation.
•Selection of air cool will be use only during MMA operation

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FUNCTION MACHINE

AC and DC
•The selection enable the operator to choose between AC or DC (-) welding
•AC selection is for aluminum and MMA AC welding process
•DC selection is for MS, SS, Copper, Brass, Titanium, etc and MMA DC welding process

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FEATURES OF ITG 300/500P AC/DC

Features:
1. Pulsed AC/DC capability with full control.
2. Full function AC/DC TIG
3. Excellent low end performance
4. Energy saving
5. High frequency start arc
6. MMA welding available
7. Over current & thermal protection with warning
indicator

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79
WIM ACCESSORIES

Automatic Firebird head shield Soft lather hand glove

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WIM WELDING ACCESSORIES

Air cool torch

WP 17, 26 WP 17V, 26V


(150amp) , (200
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WIM WELDING ACCESSORIES

Water cool torch

WP 18 ,WP 12 Earth Clamp


(300amp,500amp)

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WIM WELDING ACCESSORIES

Comment part of TIG torch

Long back cap Short back cap

Trigger switch

Collect

Collect body
Torch body

Ceramic nozzle

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WIM WELDING ACCESSORIES

WCS 33 Argon regulator

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WIM WELDING ACCESSORIES

Tungsten Filler rod

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THE END

With WIM you are not just buying


“A Welding Machine”:
•Genuine parts and consumables
•Warranty
•After Sales service

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86

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