THERMADYNE

SALES & MARKETING

NEWS UPDATE

Q3 & Q4 2009

NE W P
H TING RO
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PROGRAM

From the Desk of Martin Quinn
President

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 marcom@thermadyne.com.

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).

PAGE 2 • Thermadyne Sales & Marketing News Update

Victor products include oxy-fuel cutting and welding Table of Contents
equipment such as oxy-acetylene and oxy-fuel welding
and cutting torch handles, cutting attachments,
straight cutting torches, regulators, cutting tips, Victor Professional
welding nozzles and cutting/welding outfits. Edge Series regulator . . . . . . . . . . . . . . . . . 4-5

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

Thermal Arc offers the latest technology in MIG
welding from Fabricator series for light duty to the Bulldog testimonial . . . . . . . . . . . . . . . . . . . . . . 7
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 Thermal Arc 95 S Portable DC Welder . . . 8
complete line of plasma welding equipment, torches
and consumables.
Tweco MIG guns . . . . . . . . . . . . . . . . . . . . . . . . . 9

Tweco Spray Master Case Study . . . .10-11
Thermal Dynamics is a pioneer in plasma cutting
systems. Products include the Thermal Dynamics
CUTMASTER True Series manual plasma cutting Thermadyne Automation
systems and a full range of automation products. Cut Sample Program . . . . . . . . . . . . . . . . . . 12

FastCut testimonial . . . . . . . . . . . . . . . . . . . . 13
Stoody is a leader in hard-facing technology and high
alloy filler metals.
Plasma Retrofitting . . . . . . . . . . . . . . . . . . . . . 14

Thermal Dynamics on “Trucks!” . . . . . . . . 15
Tweco is a leading supplier of MIG guns and
consumables including the popular Tweco Number
4 and Tweco Spray Master MIG guns. Plasma Welding . . . . . . . . . . . . . . . . . . . . .17-19

Stoody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21
Arcair is the first name in Arc Gouging.

Arcair Slice training . . . . . . . . . . . . . . . . .22-23
TurboTorch offers a full line of Air fuel and Oxy fuel
torches, equipment and accessories for the plumbing
and HVAC market.

www.thermadyne.com • Q3 & Q4 2009 • Page 3

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

V ictor 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
the Victor Professional Edge Series regulator, Victor
has breathed new life into gas control technology,
giving you more value for your purchase.
highest quality gas equipment in the business. With

WARNING: THE GAS INDUSTRY IS COMING UNDER NEW REGULATION
The 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.


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 Victor Professional Edge Series regulators are a safe
meets or exceeds all requirements of UL 252. It even bet for growing your business too. This is the first
passes the stringent ASTM G-175 promoted ignition major advancement in gas regulators in one hundred
test. This is a regulator that offers unsurpassed safety. 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.

How To Order
Pressure
Series Type Capacity CGA Gas Type Model Number Part Number
(PSIG)
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


• Thermadyne Sales & Marketing News Update

“THE BEST IN THE
INduSTRY”
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 gROSmAN
Stafford, TX
www.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.

www.thermadyne.com


3/32"
115 VAC (2.5mm) MAX LIFT START

FAN COOLED THERMAL INPUT POWER STICK WELDING TIG WELDING WARRANTY
OVERLOAD

Stick Package
Part # W1003202

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 Stick/TIG Package
• Victor® CutSkill® argon regulator/flow gauge Part # W1003203

Additional Part Numbers
Product Part No. Description

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

TIG Torch
W4012500 17V 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


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.

Visit www.twecotrust.com today.


VERY COOL, INDEED One of the key features of the Spray Master MIG
gun is how cool it operates in the most demanding
Spray Master MIG Guns from TWECO 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.

L OUISVILLE, 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.


“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.


Automation Cut Sample Program
T he Thermadyne Automation group has been busy.
The interest in Thermal Dynamics plasma cutting
systems continues to be of interest to OEM cutting
Samples are usually ready within 48 hours on receipt
of request.
The samples
table manufacturers and integrators.
are packaged in
“With automation systems being so large, having a professional
demo units readily available is often impractical. For presentation cut
these instances, cut samples are used to convey sample box and
Thermal Dynamics’ capabilities to a distributor shipped UPS
salesperson or end user,” says Cutting Product Line Ground along with
Manager Kent Swart. “Some competitors charge as literature, and a
much as $500 per shipment of such samples but specification sheet
Thermal Dynamics continues to offer the program free that lists the cutting
of charge.” Here’s how the process works: parameters.
Thermadyne Automation sales manager fields the call When end users
and compiles all the pertinent data: request to see their
• distributor and end-user contact information exact part cut with an Auto-Cut or Ultra-Cut system,
• type of sample required: material type and thickness the process is very similar. A clean DXF file (no
• end user expectations, such as: weld-ability, surface
dimensions, center lines, etc.) is supplied with the
finish, squareness, speed. original request. Custom parts requests are fulfilled
within two weeks with turn around dependent on
This data is then given to the samples department
the cleanliness of the DXF file and the complexity of
in New Hampshire where the experts determine the
the part.
optimum specifications to be used to cut the samples
for the desired outcome. For example, maximizing For more information, contact your local
speed, minimizing kerf/dross, or surface finish. Automation sales representative or e-mail us at:
automation@thermadyne.com.

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


“Thermadyne FastCut CNC of British Columbia,
Canada, built a solid business selling
CNC plasma cutting systems to the

Automation entry level industrial market. “All of a
sudden,” recalls FastCut founder and
CEO Brian Gallup, “our resource for

brings its A-Game
power supplies was having delivery
problems. Thermadyne Automation
stepped in and saved the day for us.”

every day.” 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
Thermadyne Automation always listening to what we need – no
offers a full range of products
other supplier comes close. They bring
for the metal fabrication industry
including plasma cutting their A-Game every day. They invest in
from Thermal Dynamics and our customers too with cut samples and
robotics from Tweco and instructional DVDs. They’re willing to
Thermal Arc. Thermadyne attach their name to ours, which is a big
also offers Victor, Arcair advantage for a company like ours.”
and Stoody branded
equipment and processes.
Carlo Borella and Russ Gallup
www.thermadyne.com/automation/thermaldynamics
automation@thermadyne.com Partners, FastCut CNC, with a G6
(866) 279-2628 Fabricator™ and a Thermal Dynamics®
Auto-Cut 200 plasma cutter.


Retrofitting Plasma Systems on Existing CNC Systems
By John Gilbertson

W ith today’s turbulent times, both industry
businesses and individual welders are looking
for ways to get more out of the bottom line. One
10. Should Water Mist Secondary be used?
11. What will the air compressor capabilities be in
constant pressure and volume?
solution is the upkeep, repair and improvement of 12. Most important. What are the expectations? What
existing machinery. Rather than replacing a system is the expected outcome of retrofit? Are there specific
hole or slot requirements? Where is the business
that is out of order, many facilities have turned to
headed in the short and long term? Example: Today
retrofitting, extending the machine’s life cycle and
the job may require ½” but tomorrow it may be to
saving themselves capital expenditures. cut 1½”
As retrofitting has become popular, trends for The information above is critical to ensure the correct
increasing parts life has taken hold of the industry, layout of the updated table and compatibility of
including retrofitting plasma systems on existing CNC all parts. The worst scenario would be to have the
(computer numerically controlled) system tables. In manufacturer go out on location, take everything
this instance, less is more. By updating CNC tables apart, and then find out the machine doesn’t run fast
with new bearings, Controller and drives, and adding enough or there is a problem with the initial table or
a new plasma, end users avoid the high cost of the torch height lifter doesn’t work.
purchasing a whole new system. Through retrofitting,
In addition to these 12 tips, manufactures also often
not only is a facility saving a significant amount of
utilize a pre-installation checklist. Some questions this
money, but production and efficiency is increased.
checklist may address include:
One of the leading global manufacturers and • Does the customer have the proper earth ground?
marketers of cutting and welding products and
• Does the customer have consumables prior to
accessories, Thermadyne, Inc., offers several tips installation?
every customer should know prior to having his CNC • Does the customer have an adequate air compressor
System retrofitted in order to get the highest-quality and gas supply?
and most efficient installation. While the preparation process can be time consuming,
1. What is the table’s footprint? the end result is well worth it. Once installation is
2. Where does the power source sit in relation to the complete, your system will run more smoothly and
entrance of the power track? efficiently. Retrofitting plasma systems on existing
3. Is the drive a single or a dual? CNC system tables provides an excellent alternative
4. What is the controller on the table, including the serial to those not wanting (or needing) to purchase a whole
number of both the controller and table? new system. If you are still unsure if retrofitting is the
5. What is the torch height lifter, including the serial right decision for your system, manufacturers and
number? installers can provide expertise to help determine the
6. Does it have a power track (Single or Dual) or a best route to meet your production needs.
Festoon?
7. What material thickness and types of material are to John Gilbertson is an Automation Manager for
be cut? Thermadyne, Inc. He can be reached at
8. What is the input power and breaker size? 720-320-9336 or jgilbertson@thermadyne.com.
9. What gas will be used to cut with (Water Mist
Secondary, Oxygen, Nitrogen, Hydrogen-35, or Air)?


TV Coverage Draws Attention to
Thermal Dynamics CUTMASTER A120
T hermal Dynamics’ CUTMASTER A120 system
received national media coverage recently when
Thermadyne Automation partner TorchMate, one of
Additionally, the A-Series system features:
• A powerful 80% Duty Cycle to handle all-day
production cutting in the toughest environments
the top automation distributors, was featured on an • Light-weight, compact design and convenient mounting
episode of Spike TV’s, “Trucks!” feet which allow for easy mounting in any application

“Trucks!” which airs every Sunday, highlights • Valve in torch design, reducing cycle time between
parts and increasing productivity
automotive mechanics involving trucks and SUV’s,
• CNC Interface connection located on the rear of
ranging from improvement, to customizing, to creative
the power supply offering “Start/Stop” and “OK to
works. In every episode the show includes segments
MOVE” signals
pertaining to the history of those involved with racing
• Full arc voltage using an internal terminal connection
and/or customizing trucks –often including a “How It
• Software that automatically detects the torch that
Works” section. is attached and switches between automation and
On the March 29 episode, “Trucks!” workers installed manual modes
a Thermal Dynamic’s A120 system and an air scribe • Dedicated automation software, improving cycle time
onto a TorchMate table, not only highlighting the and performance
installation, but the system’s operation. With all the advantages of 1Torch and proven
CUTMASTER reliability, the new automated
Part of the next generation of Automated CUTMASTER
CUTMASTER A-Series delivers the best in
Systems from Thermal Dynamics and based on the
productivity, precision and performance on
same platform as the TRUE Series, the CUTMASTER
the market.
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.

Torchmate vehicle proudly displays Thermadyne brands and
Thermadyne Automation logos.


exceeDINg
expecTATIoNs.
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 ZIegler
K&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.

www.thermadyne.com


The Fundamentals computerized equipment. This advantage suits plasma
welding for automation purposes in which high-volume
and repeatable short duration welds are needed.
of Plasma Welding The Energy Source of Plasma Welding
The plasma gas serves as the energy source during
By Gary Reid
plasma welding, plasma gases go through the torch,

F or those who choose a vocation in plasma welding,
learning and practicing the fundamentals of the
trade never stops. A dangerous profession, welding
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
requires strict adherence to safety protocols and argon hydrogen.
continuing education throughout one’s career. So for
those who need a refresher course, let’s get back to Argon: Utilized 98 percent of the time for plasma
the basics. welding, argon breaks down and creates a plasma
stream easier than any other gas. Thus providing the
There are three states of matter – solid, liquid and gas best pilot arc and feather at the end of the torch for
– right? Wrong. Your sixth grade science teacher didn’t starting the welding arc. Additionally, argon is an inert
tell you the whole truth. Consider the fourth state of gas, which means it does not contaminate or oxidize
matter, plasma.... the base materials.
Plasma welding is a super heating of gas that Argon Hydrogen: Consisting of 98 percent argon and 2
becomes highly conductive and in welding allows for percent hydrogen. This mixture is only recommended
the transfer of an electric arc. When you pass a gas for nickel base materials such as stainless steel. The
through this electric arc, it breaks the gas down and hydrogen content in argon produces a hotter arc and
forms what is called a plasma stream. Plasma streams breaks up the surface oxides on the material being
can be seen throughout our atmosphere in several welded and also stabilizes the weld puddle. However,
common forms. For instance, lightning is caused by this gas is seldom used for the plasma, except in the
an electrical charge passing through the atmosphere case of welding thin materials at low amperage levels,
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 Now
Dr. 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


due to its erosion effects on welding accessories. The Helium: Twenty-five percent hotter than argon, helium
extra heat produced by the hydrogen significantly is used for the welding of aluminum, copper and
shortens the life of the plasma tip. copper alloys, and thick titanium. In these materials,
heat is conducted throughout the metal very quickly.
The shielding gas flows on the outside of the tip and
Helium’s extra heat provides an advantage in
inside of the shielding cup. This protects the weld
producing heat for the weld puddle faster than it is
puddle from the atmosphere and ensures the weld
being transferred away. However, since it is lighter
puddle does not oxidize. Argon is also the most
than air, helium floats away more rapidly and may
commonly used gas for shielding, followed by argon
require a gas trailer on the torch to ensure the shield
hydrogen and helium.
gas stays over the weld puddle long enough for the
Argon: Argon is the cheapest gas to use, it is heavier weld puddle to cool.
then air thus providing good shielding of the weld
Modes of Operations
puddle, and also provides good arc stability. It also
In plasma welding there are three different modes
allows for the best and longest pilot arc feather for the
of operation which are determined based on the
pilot arc. The better the feather the better the welding
current, plasma gas flow rate and orifice diameter.
arc will transfer to the part to be welded.
These are micro-plasma mode, high-current mode and
Argon Hydrogen: Used for stainless steels and nickel- keyhole mode.
based alloys. By creating a hotter arc and in turn a
Micro-Plasma Mode: Ranging from .1 to 15 amps,
hotter puddle, it will narrow the weld bead and drive
allows the welder to operate with a longer arc length
the penetration down in the base material reducing
in relation to GTAW removing the possibility of
surface tension of the puddle and allowing the
touching the electrode to the work. At low welding
increase of travel speed. In addition, it has a tendency
current levels, the arc remains stable making it
to break up the surface oxides on the puddle, creating
suitable for welding very thin materials in delicate
a more stable puddle and smoother flow.


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.
Conclusion
Plasma 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
situations. The micro-plasma mode can be used for professional to the perfect weld.
tool and die, and mold repair. Gary Reid is a retired Plasma Welding Applications
High-Current Mode: Also known as melt-in-mode, Technician for Thermal Arc, a world leader in arc
typically ranges from 15 to 400 amps and is used for welding technology. Gary can be contacted by e-mail
precision and high-level weld quality operations and at marcom@thermadyne.com
also overlay applications such as hard surfacing. With
Problem Free Torch Set-Up
a protected electrode inside the torch, it improves The following the seven tips below will help ensure a problem
good welding geometry and penetration control. free torch set-up for every weld.

This mode provides a reliable arc transfer and arc 1. Pre-purging before starting the pilot arc is essential to long
torch life, also turning the pilot arc off first and allowing the
stability. However, this technique can only be used in torch to purge before turning the machine off is essential to
keep the hot electrode from oxidizing.
conjunction with larger orifices and precise plasma
2. Always check that the gas distributor is installed correctly.
gas flow rates control to avoid burning out the plasma
3. Be sure the correct tip and tungsten for amperage are
tip. There are two ways to set the tungsten in the selected.
torch in this mode. In most cases the electrode can 4. Remember maximum amperage rating is achieved using a
flush tungsten setting.
be set flush with the end of the tip. This will give you
5. Set plasma gas as high as possible without disturbing the
a soft arc much like a GTAW arc. The second way puddle. This will deter the tip of the torch from being starved
is to recess the tungsten inside the plasma tip, this of plasma gas and burning the tip out quicker.
6. When installing parts confirm they are not contaminated with
can vary in distance not to exceed the recommended body oils or soiled surfaces.
setting in the book. By recessing the tip you will get a 7. Periodically evaluate the condition of the ground clamping
more column type arc. surface to avoid losing amperage.

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


Tweco Professional Switchable Magnetic Ground Clamp
U niversal style suitable for pipe and plate, the
Tweco Professional® Switchable Magnetic
Ground Clamp design incorporates a V-channel which
Improvements in design, configuration and materials
deliver lighter weight, greater clamping ability, less
cost and more durability. Clamps come in three sizes,
accommodates an attachment to pipe and plate in designed to handle up to 200 amps, up to 300 amps
one magnet, with an easy connect, easy release knob. or up to 600 amps.

Hardfacing and High Alloy Product Selection Guide
I ncludes 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.


S toody 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.

Earth Moving - Construction Power Plants
Applications Mode - Wear or Repair Product Process Applications Mode - Wear or Repair Product Process
Idler Rolls Metal to Metal ThermaClad 42 SAW Roll Crushers/Coal Low Impact & Abrasion Stoody 100HD / CP2000 / 103CP FCAW, SAW
Track Rollers, Metal to Metal Stoody 105B SAW Grinding Rings/Coal Low Impact & Abrasion Stoody 100HD / CP2000 FCAW, SAW
Rails & Sprockets Metal to Metal Super Build Up GMAW, FCAW Rotary Vane Wheels High Abrasion CP2000 / Stoody 160 / Vancar FCAW, SMAW
Sprockets & Gear Teeth Metal to Metal Stoody 1105 SMAW Mill Liner Plates High Abrasion CP2000 / WP2000 FCAW, SMAW
Ripper Shanks Moderate Impact & Abrasion Stoody 101HC FCAW Clinker Grinders High Abrasion Stoody 600 FCAW, SMAW
Dozer Teeth Moderate Impact & Abrasion Stoody 31 / Stoody 600 SMAW, GMAW Elbows and Veins Low Impact & Abrasion Stoody 35 SMAW
Low Impact & High Abrasion Stoody 35 SMAW Steam Valves High Temperature, Metal to Metal Stoodite 21 & 6 OAW, GTAW,
SMAW, FCAW
Low Impact & High Abrasion Stoody 101HC GMAW, FCAW
Low Impact & Severe Abrasion Borium (ATB) OAW
Low Impact & Severe Abrasion Vancar OAW, SMAW, FCAW Dredging
Low Impact & Severe Abrasion Stoody 130 / 160 FCAW
Bucket Lips & Teeth Moderate Impact & Abrasion Stoody 31/Stoody 35 SMAW Applications Mode - Wear or Repair Product Process
Pump Housings Low Impact & Abrasion Stoody 100HD CP2000 / WP2000 FCAW
High Impact Stoody 117 FCAW
Quarries - Crushing Pump Sheals & Impellers Moderate Impact & Abrasion Stoody 117 FCAW
Rotary Cutter Teeth High Stress Abrasion Stoody 160 FCAW, SMAW
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 Agriculture
Rotors & Impeller Bars Build Up / Manganese / Carbon Steel Stoody 2110 / 110 SMAW / FCAW
Crusher Hammers Moderate Impact & Abrasion Stoody 2134 SMAW Applications Mode - Wear or Repair Product Process

Jaw Crusher - Jaws Moderate Impact & Abrasion Stoody 134 FCAW Sweeps Moderate Impact & Abrasion Stoody BTS OAW

High Impact & Abrasion Stoody 600 FCAW Moderate Impact & Abrasion Stoody 31 FCAW

Joining Joining Manganese to Carbon Steel Stoody 2110 / 110 SMAW, FCAW, GMAW Low Impact & Abrasion VanCar OAW, SMAW, FCAW

Various Hammers Low Impact & High Abrasion VanCar SMAW, FCAW, GMAW Chisel Points Moderate Impact & Abrasion 965G SMAW, FCAW

Worn Cone's & Mantles Repairs Stoody 110 / 2110 SMAW, GMAW , FCAW Ammonia Injector Feet Low Impact & Abrasion Borium (ATB) / VanCar OAW, SMAW, FCAW

Build Up & HardFace Stoody 117 FCAW Mill Hammers Medium Impact & Abrasion Borium (ATB) (TB-2954) OAW

New Cone's & Mantles Moderate Impact & High Abrasion Stoody 100 HC FCAW
Oil - Petroleum
Mining Applications Mode - Wear or Repair Product Process

Applications Mode - Wear or Repair Product Process Tool Joints Medium Impact & Abrasion ThermaClad 104TJ SAW

Dragline Bucket/Shovel Tips High Stress Abrasion CP2000/Stoody 160 FCAW Hardbanding Medium Impact & Abrasion CP2000, Stoody 600, Stoody 100 FCAW

Tunneling/Boring Low Impact & Severe Abrasion Stoody VanCar 130 FCAW Valve Trim Corrosion & Abrasion Stoodite 6 OAW, SMAW,
GMAW, SAW
Conveyor Pipes High Abrasion CP2000/Stoody 160 FCAW
Rock Bits (Shirt Sleeves) High Stress Abrasion ATB-Acetylene Tube Borium-(H-Rod) OAW
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 Steel Mills
Dragline Pins Metal To Metal Stoody 102 SMAW, FCAW, SAW
Rolls Temperature & Abrasion ThermaClad Alloys SAW
Cement
Applications Mode - Wear or Repair Product Process Logging
Pulverizing Mill Raw Material Moderate Impact & High Abrasion Stoody 100HC FCAW
Moderate Impact & High Abrasion Stoody CP2000 or 2001 FCAW
Debarking Hammers Medium Impact & Abrasion VanCar OAW, SMAW, 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 Recycling
Build Up ThermaClad Roll Build 3 SAW
Mill Paddles Moderate Impact & Abrasion Stoody 35 SMAW
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


Arcair SLICE Pack Delivers Right Combination
of Power and Safety for Firefighters
L ocated 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
“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/
continuous use in the U.S. The 30 volunteer members oxygen torch. Later we changed to MAPP gas. While
of the Bristol Fire Company have roots in history we felt that we needed to have a torch available, we
but enthusiastically embrace the latest technology were always concerned about having a cylinder of
to respond to approximately 300 annual calls for flammable gas stored in the compartment on the fire
assistance with fires, rescues, hazardous material truck. In addition to the safety issues, the torch set
incidents and emergency medical calls. up and use was often difficult for the average member
because the need for the torch was infrequent. We
Members spend hundreds of hours of training in
find that the SLICE is easier to set up and use, cuts
firefighting, hazardous materials, medical emergencies
more materials faster than the fuel gas/oxygen torches
and all types of rescues including vehicle accidents,
and is safer because we are no longer carrying a
confined space, industrial accidents, trench and
cylinder of flammable gas on the fire truck. Thanks
elevator rescues. Through an Assistance to Firefighters
to the AFG program, we have a SLICE torch on each
Grant (AFG) from the Federal government, the
fire truck. We believe that the torches and the training
Company recently purchased the Arcair® SLICE® Pack,
improve our operational capabilities to better serve
a cutting system that is used predominantly for forced
our community.”
entry or victim extrication.


In coordination with our distributor Airgas, “It was great working with Thermadyne and the
Thermadyne District Business Manager Jim Henry Bristol Fire Company,” said Gina DeMario, Airgas
trained the Bristol Fire Company crew on the SLICE, Business-to-Business Associate who, with Bristol
and demonstrated the components of the torch, Fire Company Chief Deputy Fran Hufnell, set up
proper care, set up, the importance of safety and the training. “Everyone was very pleased and very
actual use of the torch. engaged throughout the entire presentation. It was
quite impressive.”


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

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

Pictured above are “Doc” Oliver of Three
800-569-0547 FAX 800-535-0557 Mules Welding Supply, and Thermadyne
www.victorequip.com 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
800-426-1888 FAX 800-535-0557 products are used to make their
www.tweco.com customized cars race ready .

“Getting involved in building
800-426-1888 FAX 800-535-0557
www.tweco.com and racing these cars has
been good for business,”
said Jimmy. “Racers from
several states have come
800-382-8187 FAX 800-535-0557 to our stores to ask us
www.victormed.com
about our work and buy
our equipment.” Three
Mules has stores both
800-426-1888 FAX 800-535-0557 in Mechanicsville and
www.thermal-dynamics.com Lexington Park, Md.

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

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

866-279-2628 FAX 800-535-0557
www.stoody.com
Q3 & Q4 2009 Sales & Marketing News

THERMADYNE

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