D/F Top Load Water-Cooled Automatic TIG Barrels

Overview

D/F Machine Specialties machine-held water-cooled TIG torches or GTAW torches are designed to meet the stringent and continuous demands of precise, high-amperage mechanized welding applications. The D/F Machine Specialties TM500-CN (Tube Mill) Top Load TIG Automated Machine Barrel is intended for semi-automatic or automatic machine applications of the tungsten inert arc process. The barrel accommodates top load of tungsten with a tubular dual collet design providing clamping pressure at two points.

The TM 500 Machine Torch Series features a heavy-duty 500 amp water-cooled power cable. This water-cooled automated TIG barrel has the unique feature of the nozzle assembly water passages being serially connected to the inner body water chamber by means of sliding removable connectors. This allows ease of maintenance and eliminates the use of o-rings or gaskets in the water passage system.

D/F Nozzles (also called gas cups) provide a given amount of shielding gas coverage to the weld pool, according to their size (anywhere from 1/4- to 5/8-inch ID). For example, a smaller nozzle provides less gas coverage than a larger one. Nozzles also vary in price and performance. Built-in gas lens/gas difusser improves gas coverage to eliminate shielding gas turbulence and improve weld quality (all models). The TM 500 Back Load TIG Torch is available in 12.5" barrel lengths to meet exact welding requirements on precise mechanized jobs. Front or back tungsten loading/tightening eases tungsten changeover and extension adjustments (all models). Internal tungsten adjustment eases fine positioning of tungsten and allows for axial movement of 1/4 inch (all models).

The most cost effective are 90 or 95 percent alumina oxide nozzles, which work adequately for lower amperage applications. These nozzles, however, do not resist thermal shock on higher amperage applications very well and tend to deteriorate or crack and fall off.

Lava nozzles cost more than alumina oxide nozzles and are more resistant to cracking. These nozzles work well on medium to high amperage applications.

The bottom line when choosing TIG consumables is to look for factory OEM parts that provide you with the durability and performance you need. A wide variety of options exist for back caps, collets and collet bodies, gas lenses and nozzles, all of which offer distinct advantages, disadvantages and cost considerations. For less critical applications, the less expensive alumina nozzles provide adequate performance. However, if you need high performance, it is well worth your while to purchase more expensive, long-lasting lava nozzles or cups. Doing so minimizes the chance of consumable failures that could ultimately increase the cost for rework associated with weld inconsistencies.

The D/F torch is famous for the fact, that if it is chilled properly, the welder can grab the chrome front water-cooled barrel (not the copper gas nozzle/cup) of the torch with their bare hand and it will be cold to the touch seconds after welding. With the proper chiller, this can be done even after a 4 hour arc time. Make certain the cooling water supply is at least the minimum flow rate of 1 gallon per minute (for each inner body), at 40 psi (80 psi maximum) with a 6 gallon reservoir and a recommended 30,000 BTU/hr cooling capacity. Gun ratings are affected by shielding gas used, arc time, cooling time and inlet water temperature. Water outlet temperature should not exceed 27°C (80°F). The torch’s water out & power cable is not cooled until the coolant has gone through the torch and out the water out & power cable. If water is not flowing through the D/F torch for at least 1 minute prior to striking an arc, when you apply the power and water hits the “hot” water/out & power cable, you will generate steam. Steam can damage the torches internals in seconds causing a leak. It can also blow out the torches water/out & power cable. A flow switch can be installed after the return line ensuring that coolant is present at the return line prior to striking an arc. When High-Deposition GMAW, high current density, high amperages, preheat, or extended periods of arc time are used, a refrigerated liquid chiller with a larger reservoir is required. Precise temperature control maintains the cooling at a constant 13°C (55°F) temperature, thus prolonging the life of the welding equipment and more specifically extending the service life of the gas nozzle and current tip. D/F Machine Specialties does not manufacture or sell chillers, we only recommend them. Click here to see our recommended chillers.

Features

• Water-Cooled Inner Body & Nozzle
• 500 Amp Top Load
• Adaptable to Any Power Source & Robotic Application
• Withstands Preheat & Extreme Conditions
• Dual Clamping Collet Provides Pressure at Two Points
• Tungsten Range .040"-5/32" (1mm-4mm)
• Gas Cup Range 1/4"-5/8" (#4-#10, 6.5mm-16mm)

Model Explanation

• TM500-CN - Tungsten Machine Barrel, 500 Amp - Ceramic Nozzle

Model Specifications

Barrel Dimensions