THERMADYNE

SALES & MARKETING

NEWS UPDATE

Q3 & Q4 2009

SPOT

LIGHTING NEW PRODUCTS • PROM

OTIONS • PROGRAMS • PE

OPLE

•

• Thermadyne Sales & Marketing News Update

From the Desk of Martin QuinnPresident

Valued Thermadyne Distributors:

We hope you will enjoy this issue of our Sales & Marketing News. This publication is dedicated to putting a spotlight on new products, promotions, programs and people.

You will note that our cover proudly displays Victor Professional Edge Series regulator which will be launched in September and available for orders in September as well. The product has an advanced design and offers outstanding flow performance. And like everything that is sold under the brand Victor umbrella it was developed with safety as a top priority. Not just Safe. Victor Safe.

The Victor Professional Edge Series regulator is an exciting product story, as are a number of other product innovations in the works for our industry leading brands. If you have the opportunity to visit with us at FABTECH AWS in Chicago, we’ll have this and a few other pieces of news to share. We’ll be located in the North Hall at exhibit space 34046.

In the meantime, we hope you will not hesitate to contact your Thermadyne representative about Victor, Thermal Dynamics, Stoody, Thermal Arc, Arcair, Tweco or TurboTorch. We are also happy to hear from you via e-mail at [email protected].

Shown here is a rendering of our planned FABTECH AWS exhibit space, which is still in development. The mural backdrop shows a number of metal cutting and welding applications. Under each arch, we’ll showcase a product spotlight area. Video will be running throughout the show with various product features and highlights.

Regards,

Martin Quinn

FABTECH International & AWS Welding Show will be held November 15-18, 2009 at McCormick Place in Chicago. The show will have 1,100 exhibitors and anticipates 35,000 visitors. Event sponsors are: American Welding Society (AWS), Fabricators & Manufacturers Association (FMA), Society of Manufacturing Engineers (SME) and Precision Metalforming Association (PMA).

www.thermadyne.com • Q3 & Q4 2009 •

Table of Contents

Victor Professional Edge Series regulator . . . . . . . . . . . . . . . . . 4-5

Journeyman fan . . . . . . . . . . . . . . . . . . . . . . . . . 6

Bulldog testimonial . . . . . . . . . . . . . . . . . . . . . . 7

Thermal Arc 95 S Portable DC Welder . . . 8

Tweco MIG guns . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tweco Spray Master Case Study . . . .10-11

Thermadyne Automation Cut Sample Program . . . . . . . . . . . . . . . . . . 12

FastCut testimonial . . . . . . . . . . . . . . . . . . . . 13

Plasma Retrofitting . . . . . . . . . . . . . . . . . . . . . 14

Thermal Dynamics on “Trucks!” . . . . . . . . 15

Plasma Welding . . . . . . . . . . . . . . . . . . . . .17-19

Stoody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21

Arcair Slice training . . . . . . . . . . . . . . . . .22-23

Victor products include oxy-fuel cutting and welding equipment such as oxy-acetylene and oxy-fuel welding and cutting torch handles, cutting attachments, straight cutting torches, regulators, cutting tips, welding nozzles and cutting/welding outfits.

Thermal Arc offers the latest technology in MIG welding from Fabricator series for light duty to the ArcMaster and PowerMaster inverter technology lines for industrial Stick, TIG and MIG welding. Thermal Arc is also a leader in plasma welding solutions with a complete line of plasma welding equipment, torches and consumables.

Thermal Dynamics is a pioneer in plasma cutting systems. Products include the Thermal Dynamics CUTMASTER True Series manual plasma cutting systems and a full range of automation products.

Stoody is a leader in hard-facing technology and high alloy filler metals.

Tweco is a leading supplier of MIG guns and consumables including the popular Tweco Number 4 and Tweco Spray Master MIG guns.

Arcair is the first name in Arc Gouging.

TurboTorch offers a full line of Air fuel and Oxy fuel torches, equipment and accessories for the plumbing and HVAC market.


Victor has been the leader in gas equipment since its humble beginnings when it was founded on the

principle of offering only the safest, most reliable and highest quality gas equipment in the business. With

the Victor Professional Edge Series regulator, Victor has breathed new life into gas control technology, giving you more value for your purchase.

WELCOME TO LIFE ON THE EDGEEASY TO USE. ADVANCED DESIGN. UNSURPASSED SAFETY. OUTSTANDING FLOW CONTROL.

WARNING: THE GAS INDUSTRY IS COMING UNDER NEW REGULATIONThe new regulation you get with the Victor Professional Edge Series regulator offers outstanding flow control. It’s easy for a regulator to maintain good flow control when inlet pressures are high, but cylinder decay is inevitable. A regulator needs to function well across an entire range of cylinder pressures. That’s exactly where The Victor Professional Edge Series regulator outperforms the competition.


How To OrderSeries Type Capacity Pressure

(PSIG) CGA Gas Type Model Number Part Number

Edge SS* 4** 125 540 Oxygen ESS4-125-540 0781-5127

Edge SS* 4** 15 510 Acetylene ESS4-15-510 0781-5132

Edge SS* 4** 15 300 Acetylene ESS4-15-300 0781-5133

Edge SS* 4** 40 510 LPG ESS4-40-510LP 0781-5135

Edge SS* 4** 125 510 LPG ESS4-125-510LP 0781-5136

Edge SS* 4** 125 580 Inert (Nitrogen, Argon, Helium) ESS4-125-580 0781-5143

Edge SS* 4** 200 580 Inert (Nitrogen, Argon, Helium) ESS4-200-580 0781-5144

* Single Stage ** High Capacity

It’s easy to use. The Edge Series regulator comes with gauges with enhanced high contrast graphics. The regulators are color-coded for quick and easy identification of gas type. They are better positioned for hand/body position while adjusting delivery pressure.

The advanced design of the Victor Professional Edge Series regulator is the smallest, lightest and most compact heavy duty regulator available on the market. The design is innovative and unique and it is a better regulator from the leading brand in gas equipment.

The Victor Professional Edge Series passes all industry standard tests including the CGA E-4 compliance testing including the Heated Oxygen Impact Test. It meets or exceeds all requirements of UL 252. It even passes the stringent ASTM G-175 promoted ignition test. This is a regulator that offers unsurpassed safety.

Victor Professional Edge Series regulators are a safe bet for growing your business too. This is the first major advancement in gas regulators in one hundred years. The design alone is sure to attract curious buyers. The functionality and performance is sure to

lock up sales. Thermadyne has created a broad marketing program to help sales of the Victor

Professional Edge Series regulator. The product comes in innovative packaging

of durable corrugated construction and a tear away window so customers can view the product while on display. Master pack orders of six (6) regulators for the same gas type are shipped along

with a display tray that is ideal for shelves or counter tops.


www.thermadyne.com

As a major equipment supplier to the scrapping industry, Eddie Grosman knows what it takes to cut through the most rugged materials. So when his customers need help with heavy-duty scrap, he recommends the Victor Bulldog torch.

“VICTOR BulldOg TORCHES ARE THE BEST SCRAP TORCHES IN THE INduSTRY,” SAYS EddIE.

Along with a great torch, the key to superior cutting performance is the right volume of oxygen supply. “A lot of companies run into problems with portable liquid oxygen bottles and their low output,” he says. Most portable liquid oxygen bottles are limited to approximately 350 cubic ft. of output per hour. “We put an external vaporizer on the bottle to boost the output to roughly 1,000 cubic ft. per hour, and that’s when the Bulldog really tears through anything,” he says.

Grosman doesn’t just rely on Bulldog torches to make the tough cuts. They’re also helping his business grow. Eddie’s Welding Equipment is the largest distributor of Victor Bulldog torches in the nation. He says, “We’ve seen consistent growth each month since we began offering Bulldog torches because they are the best.”

EddIE gROSmANStafford, TXwww.eddieswelding.com

Eddie carries the torch – will you?

THERmAdYNE, A GloBAl cuTTinG And WEldinG lEAdEr, joins the American Welding Society in encouraging individuals to practice the art, craftsmanship and professions of welding, metalworking and fabrication. Victor, Thermal dynamics, Thermal Arc, Arcair, Tweco, Stoody, cigweld and TurboTorch are among the Thermadyne family of brands that you can count on for safety, reliability and quality.

“THE BEST IN THE INduSTRY”


Additional Part NumbersProduct Part No. Description

600300Victor CutSkill Argon Regulator/Flow GaugeArgon shielding gas regulator with 5/8"-18 UNF hose connection

W4012500TIG Torch17V style TIG torch with 10' (3m) lead, 10' (3m) lead gas hose with 5/8"-18 UNF hose connection, gas valve, 25mm dinse connection and accessory kit

W4013300 20 Amp Adapter Plug & Cable

Thermal Arc, a world leader in arc welding technology, presents an incredible welding package with its 95 S. Available in Stick and Stick/TIG packages, it comes with:

• Thermal Arc 95 S Inverter welding power source (weighs only 10 pounds)

• Tweco® WeldSkill® style electrode holder with 10' (3m) lead

• 20 Amp adapter plug & cable• Operating manual• Four (4) general purpose stick electrodes• Operating manual• Easy-to-follow quick set-up DVD

The Stick/TIG package comes with all of the above plus:

• TIG Torch 17V style 10' (3m) with accessories• Victor® CutSkill® argon regulator/flow gauge

WARRANTYFAN COOLED THERMAL OVERLOAD

TIG WELDINGINPUT POWER STICK WELDING

LIFT START115 VAC3/32"

(2.5mm) MAX

Stick/TIG Package Part # W1003203

Stick Package Part # W1003202


Visit www.twecotrust.com today.

True professionals know that nothing can replace a Tweco MIG

gun. For decades, welding operators around the world have felt

the pride of owning one of the most trusted brands in the industry.

With a rich history of producing top quality professional guns like

the Spray Master and one of the most popular MIG guns of all time

– the No. 4 MIG, it’s easy to see why the Tweco name has become

synonymous with dependability and reliability. Nothing compares

to the genuine craftsmanship of a Tweco gun.


VERY COOL, INDEEDSpray Master MIG Guns from TWECO

LOUISVILLE, KY: DAE Industries, designs, fabricates and installs aircraft engine stands,

docking and maintenance access stands, and aircraft maintenance tooling. DAE has the manpower and expertise to fulfill nearly any application that requires aircraft work stands, docks, and engine stands from engineering and design, construction, installation, modification to relocation.

The company has 40 welding and fabrication stations, and was looking for improvements in MIG gun durability and consumable life. The Spray Master MIG Gun from Tweco was the answer. Led by Thermadyne District Manager Sean Norton, DAE was able to see instant improvements from their existing MIG guns by switching to the Tweco Spray Master.

One of the key features of the Spray Master MIG gun is how cool it operates in the most demanding conditions. “The extended trigger on the handle keeps my hand away from the heat of the arc especially when we switch to flux cored wires,” reports Jason Burns, one of DAE’s top welders.

The Spray Master handle is designed to stay cool, and can increase overall productivity by not overheating, or creating welder fatigue. It is also designed with a superior Cablehoz rating that can handle higher amperage ranges. This promotes better electrical flow, which reduces the heat that can be generated from poor connections or cable ratings.

Consumables such as contact tips are also a main concern when welding in any environment. The Spray Master utilizes super heavy duty contact tips that can support up to 600 amps, and when compared to standard consumables, the parts life can be up to 10 times longer, due in part, by the fact that the Spray Master has extra mass and toughness built into the diffuser and nozzle.


“We have experienced a 60-70% increase in total consumable life, which has created less downtime when changing out parts,” says Fabrication Manager Dennis Cook. (Dennis Cook is shown in photo on opposite page)

“Contact tip life has increased from 2-3 days to nearly 3 weeks,” added Jason Burns, one of DAE’s best welders.

The Spray Master MIG Gun is designed with comfort and feel in mind. It has a natural curved handle that fits well in most welders hands. Being very light weight, the Spray Master is also very maneuverable. With a conductor tube that can be rotated 360 degrees, and with several conductor tube angles to choose from, the Spray Master can be configured for nearly any application. Jason Burns also noted that “Tweco has adapted the conductor tubes on our Spray Masters, to create the perfect angle for welding.”

DAE has been using the Spray Master for more than 6 months in full time production. It was critical to find a solution that minimized production down time not only from a welder fatigue and consumable point of view, but from maintenance as well.

Dennis also shared that “Spray Master has proven to be extremely dependable and tough with zero failures to date, not even a trigger switch. As a matter of fact, we haven’t even needed to replace any liners yet either, the wire keeps feeding extremely smooth.”

The Tweco Spray Master MIG Gun was just what the doctor ordered for DAE as they considered their upgrade. It is keeping them running. Congratulations on another Tweco MIG gun conversion success story.

A special Thanks to Thermadyne DM, Sean Norton and Thermadyne Product Line Manager, Pete Anderson and DAE welder, Jason Burns and DAE Fabrication Manager, Dennis Cook for contributing to this story.


The Thermadyne Automation group has been busy. The interest in Thermal Dynamics plasma cutting

systems continues to be of interest to OEM cutting table manufacturers and integrators.

“With automation systems being so large, having demo units readily available is often impractical. For these instances, cut samples are used to convey Thermal Dynamics’ capabilities to a distributor salesperson or end user,” says Cutting Product Line Manager Kent Swart. “Some competitors charge as much as $500 per shipment of such samples but Thermal Dynamics continues to offer the program free of charge.” Here’s how the process works:

Thermadyne Automation sales manager fields the call and compiles all the pertinent data:

• distributor and end-user contact information

• type of sample required: material type and thickness

• end user expectations, such as: weld-ability, surface finish, squareness, speed.

This data is then given to the samples department in New Hampshire where the experts determine the optimum specifications to be used to cut the samples for the desired outcome. For example, maximizing speed, minimizing kerf/dross, or surface finish.

Samples are usually ready within 48 hours on receipt of request.

The samples are packaged in a professional presentation cut sample box and shipped UPS Ground along with literature, and a specification sheet that lists the cutting parameters.

When end users request to see their exact part cut with an Auto-Cut or Ultra-Cut system, the process is very similar. A clean DXF file (no dimensions, center lines, etc.) is supplied with the original request. Custom parts requests are fulfilled within two weeks with turn around dependent on the cleanliness of the DXF file and the complexity of the part.

For more information, contact your local Automation sales representative or e-mail us at: [email protected].

Automation Cut Sample Program

Thermadyne Automation specialist John Gilbertson (in black shirt) presents representatives from FastCut CNC of British Columbia, Canada with special edition framed testimonial ad.


“Thermadyne Automation

brings its A-Game every day.”

FastCut CNC of British Columbia, Canada, built a solid business selling CNC plasma cutting systems to the entry level industrial market. “All of a sudden,” recalls FastCut founder and CEO Brian Gallup, “our resource for power supplies was having delivery problems. Thermadyne Automation stepped in and saved the day for us.”

FastCut now sells Thermal Dynamics Cutmaster A Series, Auto-Cut and Ultra-Cut plasma systems with FastCut cutting tables depending on the needs of their customers.

“Whether it’s a superior cut on gauge material or heavier metal plate, Thermadyne Automation has the answer,” says Partner Carlo Borella. Thermadyne Automation also gets high marks on service. “They work with us. They are open to new ideas. They’re always listening to what we need – no other supplier comes close. They bring their A-Game every day. They invest in our customers too with cut samples and instructional DVDs. They’re willing to attach their name to ours, which is a big advantage for a company like ours.”

Carlo Borella and Russ Gallup

Partners, FastCut CNC, with a G6 Fabricator™ and a Thermal Dynamics® Auto-Cut 200 plasma cutter.

www.thermadyne.com/automation/[email protected](866) 279-2628

Thermadyne Automation offers a full range of products

for the metal fabrication industry including plasma cutting

from Thermal Dynamics and robotics from Tweco and

Thermal Arc. Thermadyne also offers Victor, Arcair

and Stoody branded equipment and processes.


With today’s turbulent times, both industry businesses and individual welders are looking

for ways to get more out of the bottom line. One solution is the upkeep, repair and improvement of existing machinery. Rather than replacing a system that is out of order, many facilities have turned to retrofitting, extending the machine’s life cycle and saving themselves capital expenditures.

As retrofitting has become popular, trends for increasing parts life has taken hold of the industry, including retrofitting plasma systems on existing CNC (computer numerically controlled) system tables. In this instance, less is more. By updating CNC tables with new bearings, Controller and drives, and adding a new plasma, end users avoid the high cost of purchasing a whole new system. Through retrofitting, not only is a facility saving a significant amount of money, but production and efficiency is increased.

One of the leading global manufacturers and marketers of cutting and welding products and accessories, Thermadyne, Inc., offers several tips every customer should know prior to having his CNC System retrofitted in order to get the highest-quality and most efficient installation.

1. What is the table’s footprint?

2. Where does the power source sit in relation to the entrance of the power track?

3. Is the drive a single or a dual?

4. What is the controller on the table, including the serial number of both the controller and table?

5. What is the torch height lifter, including the serial number?

6. Does it have a power track (Single or Dual) or a Festoon?

7. What material thickness and types of material are to be cut?

8. What is the input power and breaker size?

9. What gas will be used to cut with (Water Mist Secondary, Oxygen, Nitrogen, Hydrogen-35, or Air)?

10. Should Water Mist Secondary be used?

11. What will the air compressor capabilities be in constant pressure and volume?

12. Most important. What are the expectations? What is the expected outcome of retrofit? Are there specific hole or slot requirements? Where is the business headed in the short and long term? Example: Today the job may require ½” but tomorrow it may be to cut 1½”

The information above is critical to ensure the correct layout of the updated table and compatibility of all parts. The worst scenario would be to have the manufacturer go out on location, take everything apart, and then find out the machine doesn’t run fast enough or there is a problem with the initial table or the torch height lifter doesn’t work.

In addition to these 12 tips, manufactures also often utilize a pre-installation checklist. Some questions this checklist may address include:

• Does the customer have the proper earth ground?

• Does the customer have consumables prior to installation?

• Does the customer have an adequate air compressor and gas supply?

While the preparation process can be time consuming, the end result is well worth it. Once installation is complete, your system will run more smoothly and efficiently. Retrofitting plasma systems on existing CNC system tables provides an excellent alternative to those not wanting (or needing) to purchase a whole new system. If you are still unsure if retrofitting is the right decision for your system, manufacturers and installers can provide expertise to help determine the best route to meet your production needs.

John Gilbertson is an Automation Manager for Thermadyne, Inc. He can be reached at 720-320-9336 or [email protected].

Retrofitting Plasma Systems on Existing CNC SystemsBy John Gilbertson


Thermal Dynamics’ CUTMASTER A120 system received national media coverage recently when

Thermadyne Automation partner TorchMate, one of the top automation distributors, was featured on an episode of Spike TV’s, “Trucks!”

“Trucks!” which airs every Sunday, highlights automotive mechanics involving trucks and SUV’s, ranging from improvement, to customizing, to creative works. In every episode the show includes segments pertaining to the history of those involved with racing and/or customizing trucks –often including a “How It Works” section.

On the March 29 episode, “Trucks!” workers installed a Thermal Dynamic’s A120 system and an air scribe onto a TorchMate table, not only highlighting the installation, but the system’s operation.

Part of the next generation of Automated CUTMASTER Systems from Thermal Dynamics and based on the same platform as the TRUE Series, the CUTMASTER A-Series offers standard features to meet the needs of automated applications.

The A-Series includes the SL100 SV 1Torch with standard ATC Quick Disconnect in lengths of 25 ft., 35 ft., and 50 ft. The 1Torch start technology eliminates the electronic interference that can occur with other designs and provides quick, reliable starts and a strong pilot arc to pierce heavy plate.

Additionally, the A-Series system features:

• A powerful 80% Duty Cycle to handle all-day production cutting in the toughest environments

• Light-weight, compact design and convenient mounting feet which allow for easy mounting in any application

• Valve in torch design, reducing cycle time between parts and increasing productivity

• CNC Interface connection located on the rear of the power supply offering “Start/Stop” and “OK to MOVE” signals

• Full arc voltage using an internal terminal connection

• Software that automatically detects the torch that is attached and switches between automation and manual modes

• Dedicated automation software, improving cycle time and performance

With all the advantages of 1Torch and proven CUTMASTER reliability, the new automated CUTMASTER A-Series delivers the best in productivity, precision and performance on the market.

TV Coverage Draws Attention to Thermal Dynamics CUTMASTER A120

Torchmate vehicle proudly displays Thermadyne brands and Thermadyne Automation logos.


www.thermadyne.com

Kyle is a self-employed welder and owner of K&K

Welding in Berlin, MA. He finds that free time is difficult

to come by. That’s likely because Kyle works primarily with

aluminum. “You can pick up steel welding pretty fast,” he

says. “But aluminum is a whole different animal. If you

can weld aluminum, it opens up a lot more doors.”

With his skill in such high demand, Kyle needs flexible

equipment that he can rely on to get the job done. That’s

why he loves his Thermal Arc Inverter Arc Welder. “When

the Thermadyne representative came to my door with this

little machine, I thought there was no way it could do what

I need it to,” he said.

The power and flexibility of the Thermal Arc Inverter Arc Welder shocked him. “I welded a 4’x4’ aluminum plate, 2” thick with 4 gussets onto a plate that was 1½” thick with minimal preheat,” he says. “Now I’m asking ‘what can’t this little machine do?”

Kyle ZIeglerK&K Welding

Berlin, MA

Kyle carries the torch – will you?

THerMADyNe, A gloBAl cuTTIng And WeldIng leAder,

joins the American Welding Society in encouraging

individuals to practice the art, craftsmanship and

professions of welding, metalworking and fabrication. Victor,

Thermal dynamics, Thermal Arc, Arcair, Tweco, Stoody, cigweld

and TurboTorch are among the Thermadyne family of brands

that you can count on for safety, reliability and quality.

exceeDINg expecTATIoNs.


The Fundamentals of Plasma WeldingBy Gary Reid

For those who choose a vocation in plasma welding, learning and practicing the fundamentals of the

trade never stops. A dangerous profession, welding requires strict adherence to safety protocols and continuing education throughout one’s career. So for those who need a refresher course, let’s get back to the basics.

There are three states of matter – solid, liquid and gas – right? Wrong. Your sixth grade science teacher didn’t tell you the whole truth. Consider the fourth state of matter, plasma....

Plasma welding is a super heating of gas that becomes highly conductive and in welding allows for the transfer of an electric arc. When you pass a gas through this electric arc, it breaks the gas down and forms what is called a plasma stream. Plasma streams can be seen throughout our atmosphere in several common forms. For instance, lightning is caused by an electrical charge passing through the atmosphere breaking down the atmospheric gases.

Getting back to the significance of the basics, because temperatures of a plasma flame can reach as high as 30,000 degrees Fahrenheit, safety is always of utmost importance. By understanding the purpose and choices in plasma welding, professionals will have a clear guideline to the proper operation and applications for the trade.

Plasma Welding Then and NowDr. R. M. Gage is credited with the introduction of plasma into the welding industry in 1955, and in the 1960s, it integrated into micro-plasma and high current applications. Today’s process has grown and is primarily used in welding automation applications approximately 80-85 percent of the time.

Similar in process to GTAW or TIG welding, plasma welding offers the added benefit of not using high frequency for arc start, which can interfere with

computerized equipment. This advantage suits plasma welding for automation purposes in which high-volume and repeatable short duration welds are needed.

The Energy Source of Plasma WeldingThe plasma gas serves as the energy source during plasma welding, plasma gases go through the torch, around the electrode and through the orifice. Plasma gases include argon or argon hydrogen, but pure argon is by far the most commonly used, followed by argon hydrogen.

Argon: Utilized 98 percent of the time for plasma welding, argon breaks down and creates a plasma stream easier than any other gas. Thus providing the best pilot arc and feather at the end of the torch for starting the welding arc. Additionally, argon is an inert gas, which means it does not contaminate or oxidize the base materials.

Argon Hydrogen: Consisting of 98 percent argon and 2 percent hydrogen. This mixture is only recommended for nickel base materials such as stainless steel. The hydrogen content in argon produces a hotter arc and breaks up the surface oxides on the material being welded and also stabilizes the weld puddle. However, this gas is seldom used for the plasma, except in the case of welding thin materials at low amperage levels,


due to its erosion effects on welding accessories. The extra heat produced by the hydrogen significantly shortens the life of the plasma tip.

The shielding gas flows on the outside of the tip and inside of the shielding cup. This protects the weld puddle from the atmosphere and ensures the weld puddle does not oxidize. Argon is also the most commonly used gas for shielding, followed by argon hydrogen and helium.

Argon: Argon is the cheapest gas to use, it is heavier then air thus providing good shielding of the weld puddle, and also provides good arc stability. It also allows for the best and longest pilot arc feather for the pilot arc. The better the feather the better the welding arc will transfer to the part to be welded.

Argon Hydrogen: Used for stainless steels and nickel-based alloys. By creating a hotter arc and in turn a hotter puddle, it will narrow the weld bead and drive the penetration down in the base material reducing surface tension of the puddle and allowing the increase of travel speed. In addition, it has a tendency to break up the surface oxides on the puddle, creating a more stable puddle and smoother flow.

Helium: Twenty-five percent hotter than argon, helium is used for the welding of aluminum, copper and copper alloys, and thick titanium. In these materials, heat is conducted throughout the metal very quickly. Helium’s extra heat provides an advantage in producing heat for the weld puddle faster than it is being transferred away. However, since it is lighter than air, helium floats away more rapidly and may require a gas trailer on the torch to ensure the shield gas stays over the weld puddle long enough for the weld puddle to cool.

Modes of OperationsIn plasma welding there are three different modes of operation which are determined based on the current, plasma gas flow rate and orifice diameter. These are micro-plasma mode, high-current mode and keyhole mode.

Micro-Plasma Mode: Ranging from .1 to 15 amps, allows the welder to operate with a longer arc length in relation to GTAW removing the possibility of touching the electrode to the work. At low welding current levels, the arc remains stable making it suitable for welding very thin materials in delicate


situations. The micro-plasma mode can be used for tool and die, and mold repair.

High-Current Mode: Also known as melt-in-mode, typically ranges from 15 to 400 amps and is used for precision and high-level weld quality operations and also overlay applications such as hard surfacing. With a protected electrode inside the torch, it improves good welding geometry and penetration control. This mode provides a reliable arc transfer and arc stability. However, this technique can only be used in conjunction with larger orifices and precise plasma gas flow rates control to avoid burning out the plasma tip. There are two ways to set the tungsten in the torch in this mode. In most cases the electrode can be set flush with the end of the tip. This will give you a soft arc much like a GTAW arc. The second way is to recess the tungsten inside the plasma tip, this can vary in distance not to exceed the recommended setting in the book. By recessing the tip you will get a more column type arc.

Keyhole Mode: Ranging from 100 amps and above and is produced by using the recess tungsten in the tip and increasing the current level and plasma gas flow. This type of mode generates a powerful plasma arc, very similar to a laser beam. During welding, the plasma arc pierces through the material producing a keyhole through the part, with the molten weld pool flowing around the keyhole to form the weld

bead, thus providing complete penetration through the thickness of the part in one pass. On very thick material a joint design will be needed to reduce the thickness of the material, and multi passes in the non-keyhole mode will be needed to fill the joint.

ConclusionPlasma Welding sustained success will be determined by the diligence of its professionals to adhere to best guidelines for usage and safety protocols. We have recently seen its outstanding versatility, quality and control mainstream the application into a variety of industries including aerospace, automobile and railway repair operations. Welders always have choices during application, but recognizing the fundamentals and understanding a tool’s purpose will truly guide any professional to the perfect weld.

Gary Reid is a retired Plasma Welding Applications Technician for Thermal Arc, a world leader in arc welding technology. Gary can be contacted by e-mail at [email protected]

Problem Free Torch Set-UpThe following the seven tips below will help ensure a problem free torch set-up for every weld.

1. Pre-purging before starting the pilot arc is essential to long torch life, also turning the pilot arc off first and allowing the torch to purge before turning the machine off is essential to keep the hot electrode from oxidizing.

2. Always check that the gas distributor is installed correctly.

3. Be sure the correct tip and tungsten for amperage are selected.

4. Remember maximum amperage rating is achieved using a flush tungsten setting.

5. Set plasma gas as high as possible without disturbing the puddle. This will deter the tip of the torch from being starved of plasma gas and burning the tip out quicker.

6. When installing parts confirm they are not contaminated with body oils or soiled surfaces.

7. Periodically evaluate the condition of the ground clamping surface to avoid losing amperage.


Universal style suitable for pipe and plate, the Tweco Professional® Switchable Magnetic

Ground Clamp design incorporates a V-channel which accommodates an attachment to pipe and plate in one magnet, with an easy connect, easy release knob.

Improvements in design, configuration and materials deliver lighter weight, greater clamping ability, less cost and more durability. Clamps come in three sizes, designed to handle up to 200 amps, up to 300 amps or up to 600 amps.

Tweco Professional Switchable Magnetic Ground Clamp

Includes latest alloys, product descriptions with part numbers, application photos that demonstrate the

varied potential uses for the products. The Guide is divided into easy-to-read sections dealing with Coated Electrodes and Bare Rods, Open-Arc and Gas-Shielded Wires, Submerged Arc Wires, and High Alloy Joining and Cladding. Topics such as metal to metal wear, metal to earth for moderate to severe impact and moderate to severe abrasion, metal to earth for extreme abrasion and low impact, and abrasion accompanied by corrosion and/or high temperatures are all covered.

Ask your Thermadyne representative for a copy of this helpful Stoody Guide.

Hardfacing and High Alloy Product Selection Guide


Earth Moving - ConstructionApplications Mode - Wear or Repair Product Process

Idler Rolls Metal to Metal ThermaClad 42 SAW

Track Rollers, Rails & Sprockets

Metal to Metal Stoody 105B SAW

Metal to Metal Super Build Up GMAW, FCAW

Sprockets & Gear Teeth Metal to Metal Stoody 1105 SMAW

Ripper Shanks Moderate Impact & Abrasion Stoody 101HC FCAW

Dozer Teeth Moderate Impact & Abrasion Stoody 31 / Stoody 600 SMAW, GMAW

Low Impact & High Abrasion Stoody 35 SMAW

Low Impact & High Abrasion Stoody 101HC GMAW, FCAW

Low Impact & Severe Abrasion Borium (ATB) OAW

Low Impact & Severe Abrasion Vancar OAW, SMAW, FCAW

Low Impact & Severe Abrasion Stoody 130 / 160 FCAW

Bucket Lips & Teeth Moderate Impact & Abrasion Stoody 31/Stoody 35 SMAW

Quarries - Crushing Applications Mode - Wear or Repair Product Process

Roll Crusher-Rollers Build Up/Repairs Roll Crusher Stoody 2110 / 110 SMAW / FCAW

Build Up & HardFace Roll Crushers Stoody 117 FCAW

Rotors & Impeller Bars Build Up / Manganese / Carbon Steel Stoody 2110 / 110 SMAW / FCAW

Crusher Hammers Moderate Impact & Abrasion Stoody 2134 SMAW

Jaw Crusher - Jaws Moderate Impact & Abrasion Stoody 134 FCAW

High Impact & Abrasion Stoody 600 FCAW

Joining Joining Manganese to Carbon Steel Stoody 2110 / 110 SMAW, FCAW, GMAW

Various Hammers Low Impact & High Abrasion VanCar SMAW, FCAW, GMAW

Worn Cone's & Mantles Repairs Stoody 110 / 2110 SMAW, GMAW , FCAW

Build Up & HardFace Stoody 117 FCAW

New Cone's & Mantles Moderate Impact & High Abrasion Stoody 100 HC FCAW

CementApplications Mode - Wear or Repair Product Process

Pulverizing Mill Raw Material Moderate Impact & High Abrasion Stoody 100HC FCAW

Moderate Impact & High Abrasion Stoody CP2000 or 2001 FCAW

Pulverizing Rolls & Tables Low Impact & High Abrasion Stoody CP2000 FCAW

Feed Screw Flights High Abrasion Stoody CP2000 / 130 / 160 FCAW

High Pressure Clinker Rolls High Pressure & Abrasion Stoody 600 FCAW

Build Up ThermaClad Roll Build 3 SAW

Mill Paddles Moderate Impact & Abrasion Stoody 35 SMAW

MiningApplications Mode - Wear or Repair Product Process

Dragline Bucket/Shovel Tips High Stress Abrasion CP2000/Stoody 160 FCAW

Tunneling/Boring Low Impact & Severe Abrasion Stoody VanCar 130 FCAW

Conveyor Pipes High Abrasion CP2000/Stoody 160 FCAW

Augers High Abrasion Stoody 101HC/CP2000/160 FCAW, SMAW

High Abrasion Super 20 FCAW, SMAW

Cable Sheaves Metal To Metal ThermaClad 42/102/1102 SAW, GMAW, SMAW

Dragline Pins Metal To Metal Stoody 102 SMAW, FCAW, SAW

Power PlantsApplications Mode - Wear or Repair Product Process

Roll Crushers/Coal Low Impact & Abrasion Stoody 100HD / CP2000 / 103CP FCAW, SAW

Grinding Rings/Coal Low Impact & Abrasion Stoody 100HD / CP2000 FCAW, SAW

Rotary Vane Wheels High Abrasion CP2000 / Stoody 160 / Vancar FCAW, SMAW

Mill Liner Plates High Abrasion CP2000 / WP2000 FCAW, SMAW

Clinker Grinders High Abrasion Stoody 600 FCAW, SMAW

Elbows and Veins Low Impact & Abrasion Stoody 35 SMAW

Steam Valves High Temperature, Metal to Metal Stoodite 21 & 6 OAW, GTAW, SMAW, FCAW

DredgingApplications Mode - Wear or Repair Product Process

Pump Housings Low Impact & Abrasion Stoody 100HD CP2000 / WP2000 FCAW

High Impact Stoody 117 FCAW

Pump Sheals & Impellers Moderate Impact & Abrasion Stoody 117 FCAW

Rotary Cutter Teeth High Stress Abrasion Stoody 160 FCAW, SMAW

AgricultureApplications Mode - Wear or Repair Product Process

Sweeps Moderate Impact & Abrasion Stoody BTS OAW

Moderate Impact & Abrasion Stoody 31 FCAW

Low Impact & Abrasion VanCar OAW, SMAW, FCAW

Chisel Points Moderate Impact & Abrasion 965G SMAW, FCAW

Ammonia Injector Feet Low Impact & Abrasion Borium (ATB) / VanCar OAW, SMAW, FCAW

Mill Hammers Medium Impact & Abrasion Borium (ATB) (TB-2954) OAW

Oil - PetroleumApplications Mode - Wear or Repair Product Process

Tool Joints Medium Impact & Abrasion ThermaClad 104TJ SAW

Hardbanding Medium Impact & Abrasion CP2000, Stoody 600, Stoody 100 FCAW

Valve Trim Corrosion & Abrasion Stoodite 6 OAW, SMAW, GMAW, SAW

Rock Bits (Shirt Sleeves) High Stress Abrasion ATB-Acetylene Tube Borium-(H-Rod) OAW

Steel MillsApplications Mode - Wear or Repair Product Process

Rolls Temperature & Abrasion ThermaClad Alloys SAW

LoggingApplications Mode - Wear or Repair Product Process

Debarking Hammers Medium Impact & Abrasion VanCar OAW, SMAW, FCAW

RecyclingApplications Mode - Wear or Repair Product Process

Tire Shredding Knives High Stress, Metal to Metal Stoody M7 FCAW

Tube Grinders High Stress Abrasion VanCar OAW, SMAW, FCAW

Rotor Disc Car Crusher High Impact Stoody 110 SMAW, FCAW

Stoody is the world leader in the production of welding wires and electrodes used to combat various types of wear and corrosion. Industries as diverse as construction, mining, oil and gas, energy, steel and recycling have

come to depend on Stoody. Contact your Thermadyne representative about quality solutions in hardfacing, wire filler metals, welding alloys, arc wire, arc flux and electrodes from Stoody.


Located about 20 miles northeast of Philadelphia, the Borough of Bristol is the home of what

is believed to be the second oldest fire house in continuous use in the U.S. The 30 volunteer members of the Bristol Fire Company have roots in history but enthusiastically embrace the latest technology to respond to approximately 300 annual calls for assistance with fires, rescues, hazardous material incidents and emergency medical calls.

Members spend hundreds of hours of training in firefighting, hazardous materials, medical emergencies and all types of rescues including vehicle accidents, confined space, industrial accidents, trench and elevator rescues. Through an Assistance to Firefighters Grant (AFG) from the Federal government, the Company recently purchased the Arcair® SLICE® Pack, a cutting system that is used predominantly for forced entry or victim extrication.

“We have had a torch on one of our fire trucks for many years,” said Bristol Fire Company Chief Herb Slack. “The first torch we had was an acetylene/oxygen torch. Later we changed to MAPP gas. While we felt that we needed to have a torch available, we were always concerned about having a cylinder of flammable gas stored in the compartment on the fire truck. In addition to the safety issues, the torch set up and use was often difficult for the average member because the need for the torch was infrequent. We find that the SLICE is easier to set up and use, cuts more materials faster than the fuel gas/oxygen torches and is safer because we are no longer carrying a cylinder of flammable gas on the fire truck. Thanks to the AFG program, we have a SLICE torch on each fire truck. We believe that the torches and the training improve our operational capabilities to better serve our community.”

Arcair SLICE Pack Delivers Right Combination of Power and Safety for Firefighters


In coordination with our distributor Airgas, Thermadyne District Business Manager Jim Henry trained the Bristol Fire Company crew on the SLICE, and demonstrated the components of the torch, proper care, set up, the importance of safety and actual use of the torch.

“It was great working with Thermadyne and the Bristol Fire Company,” said Gina DeMario, Airgas Business-to-Business Associate who, with Bristol Fire Company Chief Deputy Fran Hufnell, set up the training. “Everyone was very pleased and very engaged throughout the entire presentation. It was quite impressive.”

Pictured above are “Doc” Oliver of Three Mules Welding Supply, and Thermadyne District Manager John Abbitt, at the Potomac Speedway in Mechanicsville, Md ., in front of one of the Three Mules-sponsored dirt track racecars . Jimmy Oliver, who along with his father “Doc” and brother Brian, owns Three Mules, says many of Thermal Arc’s welding products are used to make their customized cars race ready .

Q3 & Q4 2009 Sales & Marketing News

800-426-1888 FAX 800-535-0557www.victorequip.com

800-238-0282 FAX 800-535-0557www.turbotorch.com

800-569-0547 FAX 800-535-0557www.victorequip.com

800-426-1888 FAX 800-535-0557www.tweco.com

800-426-1888 FAX 800-535-0557www.tweco.com

800-382-8187 FAX 800-535-0557www.victormed.com

800-426-1888 FAX 800-535-0557www.thermal-dynamics.com

800-426-1888 FAX 800-535-0557www.thermalarc.com

800-426-1888 FAX 800-535-0557www.stoody.com

866-279-2628 FAX 800-535-0557www.stoody.com

“Getting involved in building and racing these cars has been good for business,” said Jimmy. “Racers from several states have come to our stores to ask us about our work and buy our equipment.” Three Mules has stores both in Mechanicsville and Lexington Park, Md.

THERMADYNE

Business

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