Companies and individual welders take great care – and rightly so – when it comes to choosing and using a power source.

That equipment is a big investment, and it must be appropriate for the application at hand. Additionally, the machine must be maintained diligently to ensure it will perform when needed.

But, what about the other parts of the welding system? There are factors to consider for those components as well, especially the welding torch.

The torch used for the gas tungsten arc welding process is an integral part of the welding system, and it is responsible for carrying and directing the welding current to the weld joint.

So it is important to take a few moments to consider the GTAW torch that will accompany the wellthought- out purchase of a power source.

The Torch: From the Machine Forward
Choosing a durably constructed GTAW torch that has reliable components and properly maintaining that torch can save a lot of hassle and frustration. Plus, it’ll keep you welding longer and, giving your torch purchase adequate consideration it can help to lower costs for replacements.

There is, however, no hard and fast rule for selecting the “right” torch. Rather, there are factors to consider with each component and the selection of each will depend on the individual application for which it will be used.

Here are some recommended guidelines.

The handle
The GTAW torch has to have the right handle for the job. Specifically, the handle should be comfortable to hold and should offer the appropriate cooling capacity required for the application. Generally, there are two types of handles: Smooth, which are sometimes called knurled, or ribbed.

Ribbed handles help to improve cooling capacity on air-cooled torches, and often are shipped standard from the factory when you order an air-cooled GTAW torch.

Conversely, smooth handles offer good thermal conductivity for water-cooled torches.

These two types of handles can be interchanged according to welding operator preference. However, it is important to be sure that both are made of durable electrical grade plastic. This compound helps resist cracking and protects against high frequency shocks.

If the power source being used does not have a gas solenoid, choose a torch body that includes a gas valve control. This valve can be turned on and off as needed to minimize unnecessary shielding gas usage — a definite cost saving factor.

Insulation
The GTAW torch body should feature good insulation, as protection against damage from day-to-day use. Insulation also helps to extend torch life and shields against high frequency leakage.

Ten Easy Tips for Maintaining a GTAW Torch Once you’ve chosen the most appropriate GTAW torch and components for your application, routine inspections and some simple maintenance can help make them last. 1. Use a woven nylon cable cover with a plastic zipper to protect hoses and cables from cuts caused by dragging, and to help avoid high frequency problems that can lead to torch damage. 2. Periodically remove the collet and collet body and wire brush them to remove oxides that can lead to an erratic arc and shorten consumable life. 3. Make sure all threads on connecting points of the torch are tightened properly to prevent problems with electrical conductivity that can damage the torch’s front- end parts. 4. Visually inspect the nozzle to look for distortion, cracking or blackening. These are signs of wear that can lead to improper shielding gas coverage. Replace the nozzle if any such damage is evident. 5. Check for cracks in the handle by inserting a wooden dowel or your finger into 6. the back end of the torch; this increases the diameter of the handle and makes for easier visual inspection. Replace – do not tape – the handle if it is damaged to avoid injury from shocks. 7. Visually inspect the silicon rubber insulation surrounding the torch body for any cuts. Check a phenolic torch body for cracks. Replace either torch body if any irregularities are found. Looks for cracks or signs of deterioration on the insert, or O-ring, attached to the back cap. If needed, replace to prevent aspiration (pulling of air into the torch body), as this can lead to weld discontinuities. 8. Keep the threads connecting the backcap and torch body clean, look for any signs of wear on the threads, and replace as necessary. 9. Test that power connector is snugly tightened to the power source to prevent overheating and damage to the torch cable. Also be certain all gas and water fittings are secure to prevent leaks. 10. When using a water-cooled torch, periodically remove the handle to check water connections for leaks that can lead to torch overheating and damage.

Most GTAW torch manufacturers surround the torch body with silicon rubber insulation, and some specifically use a high-dielectric type. High-dielectric silicon rubber aptly withstands higher voltages without breaking down, which helps lengthen the life of the torch. Silicon rubber insulated torch bodies are also more resilient than hard phenolic torch bodies (another torch body option) to resist cracking if dropped.

Basic construction
To ensure good arc stability and, with it, good welding performance, a GTAW torch body should feature heavy copper construction, along with highly-conductive copper components, such as collets and collet bodies.

In particular, collets and collet bodies composed of a tellurium-copper alloy offer the best conductivity. They also are more resistant to heat than standard copper, and they resist twisting or elongating to hold the tungsten more securely. A secure tungsten equals a steady arc and good weld quality.

Backcaps are composed of an assortment of phenolic compounds that have varying degrees of heat resistance.

Select a backcap that is made of compounds that fit the amperage requirements of the application.

For example, if the GTAW torch is used for generalduty applications, a backcap made of a low-temperature phenolic compound will suffice. A backcap with higher thermal resistance should be selected for more demanding applications.

Gas coverage and nozzles
If greater shielding gas coverage is required for the GTAW application, or joint access is limited, a gas lens should be added to the GTAW torch. Select a gas lens made of a durable porous media, rather than those made of multiple thin screens. These types of gas lenses are more expensive, but they last longer, and provide improved gas coverage while reducing unnecessary downtime and its associated costs.

Selecting the right nozzle for the application is also an important factor when choosing a GTAW torch.

Lava nozzles offer good crack resistance for medium-amperage application, while silicon nitrate nozzles are suited for high-duty cycle GTAW applications that also have higher-amperage. Both are more expensive than alumina oxide nozzles that are appropriate for low amperage applications, but they better resist cracking and melting.

Hoses

A GTAW torch with a flexible neck helps to improve access to difficult joints.

A gas lens with a durable porous media provides good shielding gas coverage and last longer than multiple screen versions.

Check water-cooled torches periodically for leaks that can lead to overheating and torch damage.

There are two options when selecting hoses or cables for a GTAW torch.

You can choose vinyl or rubber. These are available for air-cooled or water-cooled torches.

For either type of GTAW torch, rubber hoses and cables, especially braided ones, are recommended for their longevity and welding performance.

They offer good heat resistance – to 300-degrees F, compared to 150-degrees to 200-degrees F for vinyl – and also resist kinking. The resistance to kinking helps to prevent disruption to the shielding gas flow that can lead to problems such as porosity.

Rubber hoses and cables also maintain flexibility and durability in cold environments better than vinyl, and offer good protection against high frequency leakage.

Vinyl hoses and cables are less expensive, are and practical for light-duty GTAW applications, but they do not last as long as rubber.

Beyond the Components: A Few Final Considerations
Components aside, you’ll also need to determine whether an air- or water-cooled GTAW torch is best suited for the application.

As a rule, an air-cooled torch is a good option for lower amperage applications, under 200 amps, and a water-cooled torch is used for applications that require more than 200 amps.

Air-cooled torches are heavier because they rely on the surrounding air to cool them, so make sure to select one with a comfortable handle. It will help make the GTAW torch easier to maneuver.

Consider where the welding will take place, too. Outdoor applications lend themselves to the more portable air-cooled GTAW torch, while shop applications can accommodate a water-cooled torch and its accompanying water cooler better.

Also, flexible necks are available for most GTAW torches.

These can be ordered directly from most GTAW torch manufacturers, and should be considered when you have particularly tight joints to weld, or for welding in awkward positions.

Some torch body styles feature a modular design that allows a flexible neck to be added and different head angles to be used.

These types of modular GTAW torches work well for complex joints and for applications that require reaching a variety of different angles. Modular GTAW torches also can help to lower costs by allowing you to customize a single GTAW torch to the application, instead of having to buy a different torch for each application.

Remember, a GTAW torch, no matter the application, plays an important part in the overall welding process.

Take care to select one that meets your needs and that complements your power source. It will save time, money, and a lot of headaches.