Link to youtube video
This simple video show the finished weld of the boiler end plates.
The end Plate is 3mm which sits on 80 Nominal Bore pipe, the wall thicknes of pipe is of a similar thicknes. Note there is a second 3mm plate tack welded into the inside of the pipe. The second plate has the same hole pattern as the external plate with slightly smaller hole diameter, this gives the front view of the locomotive a stronger  presence.

Note these plates were welded using the GTAW process, you choose the process you want to weld with which is dependant on skill level, for secondary school students i fing the GMAW / Mig process to be more appropriate. Only use tig welding to weld up the locomotive if the student has the skillset to do so.

Regards
Glen Jones

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​tig welding torch setting tungsten stick out length for fillet welds
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In this video titled “tig welding torch setting tungsten stick out length for fillet welds” Stuart Graves explains the correct method to set the tungsten stick out length when performing a fillet weld. This technique is required when wilding with the Gas Tungsten Arc Welding (GTAW) process which is also known as the Tungsten Inert Gas (TIG) welding process.
The initial set up of “tig welding torch setting tungsten stick out length for fillet welds” looks at the following aspects:

Loosen back cap 0:16
Ceramic touching plate 0:27
Tighten back cap 0:28
Retract Tungsten 2mm 0:48

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Tig weld torch, Setting tungsten stick out length, Fillet welds, GTAW, TIG, Tig welding beginners, Beginners welding, Tig beginners, Tig settings, Tig start up, Tig torch set up, Operator techniques, Tig welding process
Tungsten stick out length, Tungsten preparation, Tighten back cap, Angle of approach, Travel angle, DC negative, Thoriated tungsten, Zirconiated Tungsten, Gtaw initial set up, Midland metal fab, Midland metal fabrication, Perth welding training.

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tig welding Aluminium Butt weld initial set up
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In this video titled “ tig welding aluminium butt weld initial set up” Stuart Graves explains the correct tig torch set up and choose the appropriate tig welding operator techniques for performing an aluminium butt weld using the GTAW or tig welding process. The butt weld be done using  3mm aluminium plate.
The initial set up looks at the following aspects
Tungsten stick out length 0:10
Tungsten preparation 0:22
Tighten back cap 1:10
Angle of approach 1:20
Travel angle 1:30
Filler wire 1:55
Tungsten above surface 2:30
Required amperage 2:55
Back step welding 3:40
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Tig welding beginners, Beginners welding, Tig beginners, Tig, Gtaw, Tig settings, Tig torch set up, Operator techniques, Tig welding process, Tungsten stick out length, Tungsten preparation, Tighten back cap, Angle of approach, Travel angle, Filler wire, Required amperage, Midland metal fab, Midland metal fabrication, Perth welding training, Back step welding, gtaw aluminium, Gtaw butt weld set up, Gtaw initial set up, Aluminium tig welding, Butt weld set up beginners, 

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Glen Jones
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​Benefits of AC wave balance for Aluminium tig welding
 
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In this video titled “Benefits of AC wave balance for aluminium tig welding” welding lecturer Stuart Graves explains how AC wave balance works and how the AC wave balance transforms the traditional AC sign wave into an AC square wave. This transition is achieved through the AC wave balance adjustment dial which is found on modern Transformer / Rectifier and Inverter welding machines.
 
These tig machine settings will assist all beginner tig welders with the initial welding machine set up of the tig machine when welding aluminium. You will find this welding video useful whether you are an experienced welder or a beginner fabricator.
 
Time snaps
Traditional AC sign wave 0:21
Square wave 0:44
 
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AC Wave Balance, AC sign wave, Ac square wave, Transformer, Rectifier, Inverter, Welding machines, Tig machine settings, Beginner tig welders, Welding machine set up, Experienced welder, Aluminium tig welding, Wave balance tig welding, Tig welding wave balance, The use of wave balance, Square sign wave tig welding, Altering sign wave tig welding
 
Midland metal fab, Midland metal fabrication, Perth welding training

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Glen Jones
the boiler shop.com.au

Tungsten preparation and circuit selection for tig welding different metals
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In this video titled “Tungsten preparation and circuit selection for tig welding different metals
” Glen Jones explains the correct method of tungsten preparation and circuit selection for tig welding different metal types.
These techniques will help and assist all welders when it comes to setting up a tig welding plant to weld successfully.
The tungsten preparation shown are either ball end for welding aluminium or ground to a point which is required when welding carbon steel and all other metals. Explanation is also given which circuit setting is appropriate for the metal which is to be welded.
TIG stands for Tungsten Inert Gas, which is also known as the GTAW process which stands for Gas Tungsten arc welding. The GTAW / Tig process use Pure Argon gas as the shielding gas to protect the arc from the atmosphere, Argon is an inert gas.
In this video we are looking at Tungsten preparation for tig welding different metals.
We will discuss the 2 types of Tungsten preparations and there applications.
The grinding will be performed on a bench grinder and note we only use the face of the grinding wheel not the sides.
The sharp point being prepared on this Tungsten is for welding all metals except aluminium.
When welding with this preparation, make sure you weld with DC-ve polarity . If we welded with DC+ve  polarity we would overheat and melt the tungsten, so ensure you are on DC-ve polarity. This is the preparation for all metals other than aluminium.
When we prepare this tungsten we aim for the length of the point from tip to shoulder to be approx 2.5 times the diameter of the electrode.
Now we look at the preparation for welding aluminium. A sharp point is not permitted when welding aluminium because the arc is to concentrated for the low melting temperature of aluminium. A slight chamfer on the end of a clean tungsten is sufficient. When welding Aluminium ensure you are welding using the AC circuit.
 
 
Click on the times below next to the relevant topic and the video will start at this point.
Which part of the grind stone to use 0:15
Sharp point preparation 0:20
Length of tungsten to be ground  0:36
Ball end preparation 0:50
Additional videos on my youtube channel “glen jones industrial” that you may find interesting are;

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​Regards
Glen Jones
the boiler shop.com.au