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  1. #1
    Join Date
    Feb 2011
    Location
    Fridley, Minnesota
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    376

    Default TIG cooler question for my custom build.

    So, I will be starting a new thread on building a custom cooler for my new TIG machine, as I seem to be stumbling across the parts I will need to get the thing built faster than I'm coming across the funding to buy my new EVERLAST 250LX. So here's the question. Why does a cooler have to be made of either stainless or copper? More specifically I recently read, and I can't for the life of me find the source, I think it was a website for coolant fluid, but it specifically said that a TIG cooler must NOT be made of aluminum, or have any aluminum in the plumbing, cooler element, or anywhere else in the system. Could somebody tell me why? The reason I ask is that I had initially planned on using a factory transmission cooler from a Ford f250, but to the best of my knowledge, it's aluminum. Now I'm in the process of finding a heater core, custom core, or even a small radiator, so long as it's brand new and made of brass, stainless, or copper. Just wondering why no aluminum?
    "It's not magic it's experimental, kind of like washing your hands after pooping used to be." -House

    Everlast PowerTig 250EX-arrived 1-26-2012
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  2. #2

    Default

    HI Hooda
    I think it is corrosion that seems to be the hank up. With the tig torch orifices that are so small that they can get plugged up.
    Some guys use anti-freeze for a auto with aluminum engine parts, some use distilled water only.

    Have fun
    Tom

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  3. Default

    The aluminum issue has to due with galvanic corrosion. Aluminum is much higher on the activity series than copper. The coolant will act as an electrolyte (you can add corrosion inhibitors, but still) and the aluminum will act as a sacrificial anode, donating electrons to the copper to keep the copper clean and bright, while the aluminum oxidizes as a result As part of the oxidation, it will disintegrate. Chunks of corroded aluminum will come off and plug the torch and act as abrasive in the pump.

    I built my torch cooler out of an evaporator from a window AC unit. It had aluminum fins, but the pipes were copper, and it was clean, and bright on the inside. I used plastic tubing and brass fittings for the rest.

  4. #4
    Join Date
    Feb 2011
    Location
    Fridley, Minnesota
    Posts
    376

    Default Thank you for the idea!!

    Quote Originally Posted by parkour View Post
    I built my torch cooler out of an evaporator from a window AC unit. It had aluminum fins, but the pipes were copper, and it was clean, and bright on the inside. I used plastic tubing and brass fittings for the rest.
    I just last week saw a couple of window AC units, in working order for dirt cheap. I never thought of them as a donor for this project, but now, as soon as I get the time I will go and pick up one of these. The smaller unit is only about 20" wide x 12"high, so the evaporator should be about perfect for this application. The fins were all nice and straight, so at the cost of $25.00, I call that a steal. The way it's going, all I need now are a pump, and I would like to put a pressure gauge and flow indicator on the front panel. And I'll be ready to start a new thread on the actual build. The goal will be for the unit to sit under whichever EVERLAST welder I end up buying, So it looks like a slick, ready-made package, similar to what the "big guys" offer on their high end TIG welder packages. I always have liked the color green better! Thanks again for the tip!!
    Last edited by hooda; 10-25-2011 at 03:37 PM. Reason: grammar
    "It's not magic it's experimental, kind of like washing your hands after pooping used to be." -House

    Everlast PowerTig 250EX-arrived 1-26-2012
    Everlast PowerCool W300-arrived 1-26-2012
    Everlast PowerTig 185 Micro-arrived 1-26-2012
    Everlast PowerPlasma 70-arrived 1-26-2012
    ESAB MigMaster 250-borrowed
    HyperTherm 151 AKA "The Light Sabre"
    Linde UCC-305-964 lb. of old time water cooled TIG love-SOLD-Bad MOJO
    Purox OXY/ACETYLENE

  5. #5

    Default

    I am going to try my own cooler unit, and was thinking of using some copper radiator piping. This is 1/2" copper pipe with aluminum cooling fins - and if I build a serpentine array with that pipe, and have the fluid pumped through, it should cool pretty well. I might mount a few PC fans to blow air through, have a reservoir tank, and coolant pump, and voila! Cooler.

    Either that or pop the $400 and get one that just plugs in. I might have to do that since I need a quick start once I get the 250EXT.

    Cheers,

    Mike

  6. #6
    Join Date
    Mar 2011
    Location
    Eastern Oregon
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    681

    Default

    Quote Originally Posted by Mike J View Post
    I need a quick start once I get the 250EXT.
    If you have a faucet or hose bib and a drain near the welder, you can just run tap water through it for cooling. The EXT has hose barbs for in and out, so a few bucks worth of fittings + hose gets you going.
    Penncrest Buzzbox - Infinite amp control! Man the 70's were good.
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  7. #7

    Default

    Im doingthe computer fan route as well, just got an old power source, going to the pick n part to get an ac condensor or oil cooler, then a fish pump and ill fab a tank.
    Journeyman welder
    250EX
    Power plasma 60
    horizontal band saw
    Miller digital elite 'wicked' lid

  8. #8

    Default

    Quote Originally Posted by jerky View Post
    Im doingthe computer fan route as well, just got an old power source, going to the pick n part to get an ac condensor or oil cooler, then a fish pump and ill fab a tank.
    Don't mix metals. Keep it all copper or brass.
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

  9. #9

    Default

    so ive been sourcing parts, looking into computer fans to cool the condensor, and ive found fans for 4$ a pop.but i wonder if this 130$ computer cooler would be enough? ( http://www.memoryexpress.com/Products/MX33765 ) has two fans built in already, copper core,pump, all a guy would have to do is cut the tubes, put a res in and tie it into the torch. not bad for the price
    Journeyman welder
    250EX
    Power plasma 60
    horizontal band saw
    Miller digital elite 'wicked' lid

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