Welding Tips and Tricks

I have been a hobby welder for many years stick and mig and have recently taken a welding class to get better, correct mistakes and learn more about tig welding. I want to buy another machine now that has ac/dc for welding aluminum. I don't plan on welding miles of aluminum but my teacher said if I'm going to weld aluminum, more than 1" at a time, I have to have a water cooler and torch. She said an air cooled torch will just burn up in no time. I have watched piles of videos and most never mention having a water cooler. So the question, is the water cooler and torch a must? Just want a 2nd option really, I trust her and she has been a professional welder for 39 years just seems strange I wouldn't have heard more about the coolers in the videos I have watched.

Not hearing about water cooled torches may just be the fact that they are so common, and unless you'll be focusing on welding thin (~1/8"or less) aluminum then a water cooled torch is just SOP.

As you weld more you can verify this for yourself, when the torch gets warm and you have to stop for awhile. Depending on what your welding then maybe (or not) you have this luxury of time.

There are threads and YT videos on making your own water recirculator if a DIY project is what you like. Also a water cooled torch is typically lighter.

it really comes down to the amps your running and the size of the torch you want to use.
trouble is once you start getting over 1/8" aluminum you start running into the limit even on the big 26 torches which are about 200 amp.
thats when the water cooled ones shine. a water cooled 200 amp torch is really small.
the 26 i have is like using an a big heavy axe to shave with.

if you only have a 200 amp welder a 26 torch will work just fine and will not burn up any time soon.

It becomes a numbers game. The cost of a water cooled setup ( factory bought) can easily add $1000. To the cost of a welding setup. But replacing an air cooled torch is more like $100. So you can replace several air cooled torches for the cost of a water cooled setup.

1enick72 wrote:just seems strange I wouldn't have heard more about the coolers in the videos I have watched.

You simply may not have noticed the coolers in the videos. But if the torch was small, and the lines were real flexible (like more flexible than a telephone pole), you can bet they were water-cooled torches.

A water-cooled torch is generally way more flexible than air-cooled, which can be like wrestling an alligator IME. (If you get a water-cooled torch, I would recommend the rubber "superflex" hoses.) Air-cooled torches also get HOT, like too hot to hold with gloves, fast if you're welding at high currents.

You can buy a HTP water recirculator with the required 2 gal of coolant for about $500, and then the cost of the torch of your choosing.

A 25' CK200 torch with super flex hoses is under $170 on Amazon, this torch is rated at 250 amps, 100% duty cycle AC or DC

Thanks for the info guys. I'll just buy the cooler and torch set up and be done.

1enick72 wrote:Thanks for the info guys. I'll just buy the cooler and torch set up and be done.

I think you'll be very happy with water cooled.

I used air cooled 26 for a couple years and melted down several of them.
Too impatient and trying to finish is hard on them...

Once I made a water cooler and switched to 20 series, I've not looked back. Love them