DIY Network

Using a TIG Welder Chair frames are connected From "Freeform Furniture" episode DFFF-107

Host Amy Devers demonstrates how to weld the side frame and then how to position the jig to receive the stretches. She then welds the stretchers to the frame and the feet to the bottom of the dining room chairs.

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	Figure A
	Figure B
	Figure C
	Figure D

FYI: The Tungsten Inert Gas (TIG) welder generates heat from an electric arc between the electrode at the tip of the torch, the filler rod, and the metal part that's being welded (figure A). The electrode is made from tungsten and tungsten is the same material in light bulbs, but instead of creating light, it's creating heat--enough heat to melt metal. That is basically what welding is--heating metal.

There is a grounding cable (figure B) that clips on to the work piece itself, or the welding table. It acts just like the lighting rod on the roof of a barn. It takes the excess electricity, conducts it down the cable to the frame of the welder and neutralizes it.

In order to create a strong weld, you don't want any contaminates to get into the metal while it's in liquid form because that will weaken the weld and cause cracking over time. Inert gases are gases that don't combine easily with other elements--like metal. The inert, argon gas in the tank is pumped through the welder to the tip of the torch where a small amount is released. This creates a gas shield around the weld keeping out any contaminates until the metal hardens.

TIG welders range in price from $1,000 to $3,500, but you can rent one from an industrial rental supply company.

Welding involves an electric current that instantly generates 1,600 degrees of heat and a flash of light that's so bright it could blind you. A welding mask (figure C) protects your eyes from the flash of light and it covers your entire face and part of your neck as well. You also need to protect your hands and arms by wearing leather welding gloves and a long sleeve leather welding jacket. This is important because the bright light can actually burn you just like sunburn. The sparks are five times hotter than the chop saw.

Metal warps from the extreme heat when welding. This can throw things out of whack, so in order to keep the warpage to a minimum, and to keep all of the parts perfectly aligned, you can construct a jig (figure D) using scrap angle iron. Pieces of angle iron can be cut to match the drawing and then simply tack-welded onto the table. A tack weld is a temporary weld used to hold a piece in position until a permanent weld can be made.

Host Amy Devers explains the TIG welder and then uses it to connect the chair frames.

Materials:

Industrial felt
Low density polyethylene
1/2" diameter stainless steel rod
Face shield
Work gloves
Tank of argon gas
Welders mask
Welding gloves
Leather welding gloves
Weather welding jacket
Filler rod
Industrial spray adhesive
Blue tape
Utility knife
Large piece of cardboard
Industrial construction glue
Tape measure

Tools:

Metal-cutting chop saw
TIG welder
Welding jig
Water-jet cutter
Clamps
Drill press
Mallet
Cauls

	Figure E
	Figure F

Using a TIG Welder

• You need to use a tack weld to hold the jig in place while you weld the chair frame together. This is crucial when you make more than one chair because you want them to turn out exactly the same.

  Note: A great feature of some welders is the remote amperage control. It allows you to adjust the amount of heat while welding using a foot pedal.

• Once the welder is in the proper position, tack weld one side of each joint using the filler rod. The tack welds keep the work piece from over heating and warping until the permanent weld is made. The melted metal rod fills in the space between the joint creating a strong weld--hence the name filler rod.

• After each weld take a wire brush and clean off the blue burn mark from the weld (figure E). This reduces the amount of polishing needed to remove the discoloration later.

• When it cools down, take it out of the jig and flip it over and weld the other side of the joint.

• Repeat the process, welding the rest of the pieces of the chair frame together.

• Attach the front and back cross members. Use another jig to put the two halves of the frame in the upright jig and then place the front and back cross members in the trough of the jig. Using the filler rod, weld the cross members to the frames (figure F). Use a tack weld to hold them together.

• Clean the weld, fill in the weld and then clean the weld again.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Plastics
Poly Hi Solidur
Website: www.polyhisolidur.com

Welding Tools and Accessories
Steiner Industries
Website: www.steinerindustries.com

Miller Electric Manufacturing Co.
Website: www.millerwelds.com

Smith Equipment
Website: www.smithequipment.com

Waterjet Services
Flow International Corp.
Website: www.flowcorp.com

Greek Marble, Inc.
Phone: 323-221-6624

GUESTS :

Elliot Monson
Senior Applications Technician
Flow International Corporation
23500 64th Ave. S.
Kent, WA 98032
Phone: 253-850-3500, ext. 593
E-mail: jbailey@flowcorp.com
Website: www.flowcorp.com