TIG welding accessories and related items required to weld can require the largest cash expenditure besides the welder purchase itself. Items needed are basic consumables like Cups, collets, back caps, tungsten, and gas lenses. Consider byying these in full box volume. The overall cost per item will be lower when bought a box or full package at a time, and the peace of mind is well worth the extra cash. Many welding supply stores will sell partial box quantities of each, yet they can charge up to 50% more for small lot items. Usually items such as tungsten can be economically in 10 packs. Collets and cups can be bought in 5 and 10 packs as well. Gas lenes are usually sold individually and last for some time. However, different sizes should be considered along with the appropriate cups. These quantities are manageable for most small shops and home garages.

Cups are the ceramic nozzles that train the flow of shielding gas. They are fragile by nature and dropping the torch, overheating it, or any mistreatment will result in breakage. Fortunately, when bought in box quantities, the price is manageable. Multiple sizes will be required to suit different parameters such as joint type and amperage. Gas lenses help improve gas flow, and special designed cups are used with gas lenses. If a gas lens is purchased, then an extra assortment of cups will be required.

Collets hold the tungsten securely in place while welding and allow shielding gas flow to pass through to the cup. Collets are sized to match the corresponding tungsten diameter. Collet bodies hold the collets and the tungsten tightly as the back cap is tightened against the collet. They are usually sized to correspond to the appropriate collet size, however some collet bodies will work with multiple sizes of collets. Collet bodies aren’t as prone to damage as collets, and only a few of these are needed, one or two per collet size. However, collets can be damaged from the heat and from inexperienced welding techniques. 5-10 of each size to start would be ideal.

Back caps come in short, medium and long lengths. This allows greater flexibility in reaching tight areas. While fairly resilient, they can break through mishandling or over tightening. At least a couple of each size should be kept in inventory. These are usually purchased in single lot quantities.

After securing the appropriate TIG welding PPE to be able to safely weld, the next step is to prepare the welder station. To get started, the power supply must be properly wired to input volt and amp requirements of the TIG welder you have purchased. It’s actually cheaper to buy a welder that matches the power supply that you already have. But in a home garage or small shop, the correct receptacle may not be present that meets the wiring codes for a welder. An electrician who knows and understands the NEC section 640 should be hired. Wiring requirements for welders are much different than for appliances. De-rating is allowed to match the duty cycle of the welder, and breaker requirements are different as well. Welders are wired differently as well. For example, a welder running on single phase 220/240V power requires only two hot wires, and a ground wire. No neutral wire is used.

GTAW Process: Proper Wiring

A 3 prong NEMA 6-50 plug is usually recommended and is the standard plug for most welders. Depending upon your existing wiring, this may be a considerable initial expense. Consider having an extra outlet or so for your welder or additional purchases put in at the time the electrician is on site to reduce additional costs later. An outlet every 25 ft is a good starting point. If not, make sure it is centrally located to where most of the welding will be done. Extension cords for welders are not a good idea. The welders should be plugged directly into the outlet whenever possible. Note that many TIG welders have an additional grounding requirement to help reduce issues with High Frequency interference. This usually requires a second bonded ground that is connected to a ground wire directly to a copper or steel rod driven into the ground that is connected to the rear of the machine via a separate cable. Keep in mind, a licensed electrician should always be consulted and codes followed.