Welding wire ends

Loss Prevention

This should only be followed by someone with moderate knowledge of TIG welder and welding safety. Do not attempt to use this SOP as a comprehensive guide to welding and the associated risks.
Training on gas cylinders must be completed before use of them
Proper training on safe operation of a welder should be done with a certified individual.
Wear long sleeve, non-flammable, cotton clothes.
Be aware of nearby sand or class D fire extinguishers for control of metal fires.
Always ensure the welding mask is set to the appropriate shield level for the selected amps.
Take care in handling the welded wires as heat is generated quickly and distributes throughout the wires.
Avoid contact with the ground cable and arc during welding.
Gloves are not necessary but can be used. Leather welding gloves are recommended.

Select a .040" Ceriated Tungsten electrode. Grinding the tip to 30° with a grain parallel to the length of the wire. Belt sander is appropriate for this.
Prepare the ends of the wires by straightening them and sanding the surface oxide off 2" from the end of the wire.
Sand the working area of the work table to remove any oxide. Wash the area after sanding as well. Dry thoroughly.
Clamp the wires to the table such that they are parallel with each other and overlap by 1/8" of an inch, touching by the sides. Clamps should be 2-3" from the contact area of the wires. Plastic clamps are required for this.
Clamp the ground cable from the welder onto the work surface in an area that has been cleaned and is near the working area.

Insert the tungsten into the torch. Secure it such that there is 2-3x the diameter of the wire in stick out.
Turn on the Miller 200 welder by flipping the switch in the back.
Turn on the connected argon tank. A gas flow rate of 30 CFM is recommended for welding.
Position the foot pedal underneath the work area such that it can easily be reached by the operator.
Retrieve your welding helmet and set it to an appropriate level for the intended current. Shield level 9 was used here for 8 amps.
Set the welder settings to the recommended settings for Mg as provided by the quick-start guide near the welder. A amperage of 8A is recommended for 1/16" Mg wire to start.
All other settings can be left as is and changed as needed to adjust.

Set up in front of the secured wire ends. Find a comfortable position for welding.
Lower the helmet to cover your face.
While holding the tungsten electrode 1/4" away from overlap of the wires, depress the foot pedal to start the gas flow and power the welder.
The arc will begin and begin etching to remove oxide from overlapped area. Soon the area will stabilize and a high pitch, consistent buzz will be heard indicating the arc has stabilized. If it does not, stop the arc and adjust the settings.
Begin waving the arc over the intended melting area and heating the metal.
Melting will be indicated by flowing metal and a shiny melt pool. Note when this occurs in the overlapped area and continue heating for 4-5 seconds following this.
After sufficient melting of the overlapped joint, release the foot pedal but do not remove the torch. The arc will cease but gas will continue to flow.
After gas stops and the metal has cooled, release the wire clamps and observe the welded joint. Note whether or not full fusion has occurred throughout the thickness of the wire.
If there is insufficient melting of the wire, continue the welding process while adjusting parameters until full penetration of the wire has occurred.
Repeat this process with joins to obtain a full length wire. Sanding the joins may be necessary to reduce the diameter of the wire to desired size.

When finished welding, turn off the welder in the back and close the argon tank.
Clean up any remnants of wire that may have been created during the welding process. Clean up the welding work area of any oxides and other debris.
Wrap up the torch, ground table, and other wires and hand them over the weld cart
Turn off the weld mask and return it.
After ensuring all gas and welders is off, turn off the lights to the lab and leave.