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TIG Welder

Steve Frazier

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I've gotten to the point where I'd like to invest in a TIG welder. I'm starting to do sheet metal work in both stainless and cold steel and would like to be able to weld aluminum up to about 1/4 inch. I've got a Hobart Ironman 230 MIG and a gas driven stick welder. I'm a hobbyist, repairing and fabricating for my own use and have a couple vehicles I'm working on restoring.

What would be a good unit for my needs? Can a TIG pen be added as an accessory to the MIG? I'd consider a used machine too, my needs are occasional. Thanks!
 

Labparamour

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Sep 6, 2013
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810
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Washington
You might want to search WeldingWeb.
When that question comes up, the recommendation is often a harbor freight machine- they say quality is decent and warranty solid.
Aluminum tig requires hi-freq AC.
MIG runs DC. Your Ironman will run a spoolgun, won’t it? TIG is certainly nice for thin material vs MIG.
If you follow _weldman, you’ve seen the repairs he makes on aluminum trailers.
I have a small Miller TIG w 160max output.
Handles 1/16 and 1/8” aluminum okay w argon but not enough juice for thicker material.
I’m a hobbyist, too.
Others with greater skill/knowledge will point you in the right direction.
Darryl
 

Steve Frazier

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My Hobart actually came with a spool gun. I haven't used it yet. I've seen poor results MIG welding aluminum even from "professionals", that's why I figured TIG would be better for that.
 

JBrady

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Jan 24, 2019
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321
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NE OK
On your gas driven welder, you should be able to setup a lift start tig to get you started tig welding on anything except aluminum. You can use an air cooled tig whip and set your machine to constant current. If you already have a bottle of Argon and a regulator, you could be tig welding for a couple hundred bucks. To tig weld aluminum without breaking the bank, you can look for an old Miller Dialarc with high frequency. You should be able to find one for $500. They are big and heavy, but run off of 240V single phase and actually weld very smoothly. If you want to buy something newer or smaller, one of the inverter type welders are pretty reasonable. There are a ton of Youtube reviews out there and it seems like this is one area where the overseas stuff is very competitive to the blue and red machines.
 

Welder Dave

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For aluminum you probably want a foot pedal to control amps. Some welders use a control on the torch. Aluminum takes a lot more amps than steel. If you want to do 1/4" aluminum you need over 250 amps of AC current. You also need high frequency. Inverters are the cats *** when it comes to Tig welding, especially aluminum and they use a lot less power. There are some good overseas inverter Tig welders. A lot of people have good things to say about Everlast welders and even Harbor Freight Tig welders. One of the Tig specialists on the Welding Web helped with the Harbor Freight Tig welders. Miller Dynasty series are really good if you found a used one. Make sure it works properly though. A Miller Dialarc 250 HF isn't a very good Tig welder but a Syncrowave 250 is a good Tig welder. A Lincoln Square Wave 255/275 is also very good. Lincoln had a Square Wave 175 that would be good for 1/8" aluminum but doesn't have a very high duty cycle when maxed out. If you find something post it and we can tell you if it's decent or not.
 

chidog

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wa
To tig weld aluminum without breaking the bank, you can look for an old Miller Dialarc with high frequency. You should be able to find one for $500. They are big and heavy, but run off of 240V single phase and actually weld very smoothly.
This is how I went. Reason number one, no fancy electronic boards and modules. You can run one on 240 single phase, and 50 amp breaker, you just don't have full power if it is a 300 amp machine.

The new fancy inverter machines with all the various wave forms are nice.
It used to be a 700 now its an 800, this is the one I'd rather have. But I did not win the powerball, nor do I have good reason to have it. The dialarc is just fine. Oh and the Old Lincoln ideal arc is suppose to be okay, and equivalent to the dialarc in size and power use etc. Just make sure they are HF units, I think both come in 250 or 300 amp.


 

Coaldust

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Big trucks is what I know. HAZMAT is what I tow.
The two R/stamp shops I work with use Miller 252 machines for cargo tank shell repairs and for 6061 tubing work.

When I was at the oil company, Miller Dynasty 300 tig machines were the thing. Seems they were often broke down, so you needed two of them.
 

Old Doug

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Mo
I bought a used miller . It had been a while so i thought i would just have the owner weld some thing with it and i would watch but he was showing some thing else he was selling and told me to try it . I did and it was like riding a bike . I bought it the argon tank didnt go with it so it was a while before i got one. I got it set up but some thing is wrong . It will not arc unless you touch the tungsten to the work ? I need mess with it some and or get some one to look at it. There is a freight salvage store near me that has had lots of tig rods cheap so i am stocked up .
 

MistyRodriguez

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Oct 15, 2025
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america
This is how I went. Reason number one, no fancy electronic boards and modules. You can run one on 240 single phase, and 50 amp breaker, you just don't have full power if it is a 300 amp machine.

The new fancy inverter machines with all the various wave forms are nice.
It used to be a 700 now its an 800, this is the one I'd rather have. But I did not win the powerball, nor do I have good reason to have it. The dialarc is just fine. Oh and the Old Lincoln ideal arc is suppose to be okay, and equivalent to the dialarc in size and power use etc. Just make sure they are HF units, I think both come in 250 or 300 amp.


geometry dash lite
Thank you so much;)
 

Welder Dave

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I bought a used miller . It had been a while so i thought i would just have the owner weld some thing with it and i would watch but he was showing some thing else he was selling and told me to try it . I did and it was like riding a bike . I bought it the argon tank didnt go with it so it was a while before i got one. I got it set up but some thing is wrong . It will not arc unless you touch the tungsten to the work ? I need mess with it some and or get some one to look at it. There is a freight salvage store near me that has had lots of tig rods cheap so i am stocked up .
Try laying the Tig torch parallel with the part you're welding and then tilt it up till the tungsten gets close to the metal. It's common to have to scratch/ touch start a Tig torch. High frequency start for steel helps and needs to be continuous on aluminum. Don't know what welder you have but if it's made for Tig welding should have a switch for high frequency with 3 positions, off, start and continuous. Some newer machines have lift arc starting where you touch the tungsten and the arc starts when you lift it slightly off the plate. If you have a foot pedal (or hand amptrol) you need to step on it to get current.
 

Old Doug

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Try laying the Tig torch parallel with the part you're welding and then tilt it up till the tungsten gets close to the metal. It's common to have to scratch/ touch start a Tig torch. High frequency start for steel helps and needs to be continuous on aluminum. Don't know what welder you have but if it's made for Tig welding should have a switch for high frequency with 3 positions, off, start and continuous. Some newer machines have lift arc starting where you touch the tungsten and the arc starts when you lift it slightly off the plate. If you have a foot pedal (or hand amptrol) you need to step on it to get current.
It has a foot I need to try it agin . Its been a while I cant remember a lot about what i tried but I remember when i tested it that i didnt have to have the tungsten very close to the work and it arced but when i tried it at home I had to touch the tungsten and it really messed it up were it needed to be ground to a point agin.
 

Willie B

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I bought 14 years ago a Miller Diversion 180. The manager at Airgas assured me it'd be a fit for me. I wanted to weld aluminum. I found it to be a great little welder except for low duty cycle. I probably was able to weld 6" outside corner joint on 16 gauge aluminum sheet before I had to give it a rest.
I found it to be a great steel welder, but steel was not my primary material. Steel doesn't require as much power as aluminum does.
My son bought a Primeweld MIG, loves it.
I feel if I wanted to TIG steel, I might choose a Miller Dialarc 250HF, or Lincoln Idealarc equivalent. Older transformer based machines are great for steel TIG.
 

HarleyHappy

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If you have the room and the power abilities, you will not be disappointed with a Miller Dial arc HF or a Miller Syncrowave, with the latter having Squarewave technology, which is better than straight waveform.
A Miller Dynasty would be the cats meow. The new inverter stuff, I hear is awesome but I grew up with transformer welders and will die with them.
Too old to learn all them buttons.
 

Willie B

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If you have the room and the power abilities, you will not be disappointed with a Miller Dial arc HF or a Miller Syncrowave, with the latter having Squarewave technology, which is better than straight waveform.
A Miller Dynasty would be the cats meow. The new inverter stuff, I hear is awesome but I grew up with transformer welders and will die with them.
Too old to learn all them buttons.
I now have a Miller Dynasty 280DX. It is a great welder, 13 years I've had it I believe. A steel TIG does not need the features an aluminum TIG needs. You might use an air cooled torch for steel, You pretty much need a water cooler & water cooled torch for aluminum welding. I did weld aluminum with a Dialarc 250HF. The sine wave fixed at 60 HZ is not ideal for aluminum, you'll love a transformer for steel. Transformer based welders are very power hungry, while inverter based use half the input power. Some worry about all the electronics in an inverter welder being undependable.
If you want to also be able to weld aluminum, look for:
High ampere output.
High duty cycle. Most are rated with duty cycle at less than full output, a 300 amp peak welder might have a 60 % duty cycle at 200 amps. Look for the best duty cycle.
I want square wave supply, with adjustable balance. Aluminum is mostly welded with AC power. Sine wave power dies twice per cycle, 60 cycle dies 120 times per second. Shielding gas is a poor conductor, it must be ionized to be more conductive. Electrons are concentrated in the Electrode Negative half cycle. They are very effective at ionizing the gas. Electrode Positive half cycle, electrons are less concentrated on the greater surface of a workpiece, less effective at ionization. Square wave, the current never dies, it only changes direction, ionization isn't lost. HF, an overrunning High Frequency at high voltage / low current helps to maintain ionization.
Adjustable frequency is a nice feature. High frequency narrows the arc cone, low frequency gives more penetration.
 

Welder Dave

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I would not want a touch start TIG nothing, good way to pollute the electrode. HF is mandatory for Tig.
My opinion.
There is no arc on newer machines with touch start Tig. The arc starts when the tungsten is lifted. A minor touch won't contaminate the tungsten to where it has to be cleaned. There are thousands of x-ray pipe joints done in the field with Tig using just a plain DC engine drive welder. Touching the tungsten is inevitable and it won't be very often with experienced welders.

As far as Tig welders a Dialarc HF is a basic low end machine for Tig. It will work but if you went to a Syncrowave would be a big step up. The Dialarc HF machines were being blown out at discounted prices when the Syncrowave 250 came out. I've heard a Lincoln Idealarc with high frequency is nicer than a Dialarc. Idealarc's are a little better for stick welding too. I guess it depends on how much you want to spend.
 

chidog

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Snycrowave ? I see many forsale cheap at times, but they are in need of circuit boards.
There are places that fix them I suppose but?
 

Willie B

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There is no arc on newer machines with touch start Tig. The arc starts when the tungsten is lifted. A minor touch won't contaminate the tungsten to where it has to be cleaned. There are thousands of x-ray pipe joints done in the field with Tig using just a plain DC engine drive welder. Touching the tungsten is inevitable and it won't be very often with experienced welders.

As far as Tig welders a Dialarc HF is a basic low end machine for Tig. It will work but if you went to a Syncrowave would be a big step up. The Dialarc HF machines were being blown out at discounted prices when the Syncrowave 250 came out. I've heard a Lincoln Idealarc with high frequency is nicer than a Dialarc. Idealarc's are a little better for stick welding too. I guess it depends on how much you want to spend.
13 or 14 years ago I still had a lot to learn about TIG. I asked everyone I could find. Dealers felt Syncrowave was the Rolls Royce of TIG machines. At the time the 250 was well over $5000. Airgas in Rutland told me about the Dynasty 280 new to the market. I had heard of the Miller Dynasty series, I wasn't believing a mailbox sized welder would do what an 800 LB would. They assured me it would. It certainly does!
I've never actually used a Syncrowave, I do know it lacks a few features I consider important. Like any new invention, it gets refined, a better model comes to market, rendering the Syncrowave obsolete. My Dynasty weight 54 LBS, cooler about the same. It puts out 280 amps at 60% duty cycle. I love the Dynasty, but there are others with better prices.
 
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