Miller took us aside today at the SEMA Show to unveil their brand-new Diversion 165 AC/DC TIG welder and we must say it is pretty cool. If you are like us, you are probably more comfortable using a MIG but have always wanted to jump up to TIG welding for the ability to better control heat input, a much cleaner weld and a wider range of metals. However their increased complexity has kept us away. The Diversion 165 is designed specially for first-time TIG welders and has been greatly simplified with one main dial for thickness and an AC/DC switch. Included with the 165 is a TIG Welding for Dummies book along 45-minute instructional DVD. The foot pedal has also been replaced with a thumb control on the torch to make welding inside of chassis or vehicles simpler. It is also smaller weighing only 50 lbs. and has a low-price on $1,617.

The Diversion 165 is a TIG welder specifically designed for the personal user along with a first-time user making it unique. Also making it unique is that while cheaper it is not a low-end welder and features many of the same features and technology as Miller’s more professional TIG welders. It definitely makes us want to get our hands on one and give TIG a try.

The following is Miller’s official release on the welder with plenty of details:

To encourage personal users in the motorsports market to take on TIG welding projects, Miller Electric Mfg. Co. has introduced its DiversionÔ 165, the easiest-to-use, most affordable AC/DC TIG welder ever available.

The Diversion 165 features just two controls¾one for heat input and one for selecting metal type¾and has a list price of $1,617. In addition to simplicity and affordability, the Diversion 165’s stable arc and positive arc starts make it easier for beginners to achieve good results.

The Diversion 165 weighs 50 lbs. (90 lbs. less than other units), connects to 230 V, 1-phase power using a “dryer-type” 3-pronged plug and only needs a 25-amp circuit breaker to produce its full welding output of 165 amps (150 amps at 20 percent duty cycle).

The Diversion 165 can weld material as thin as 22 gauge and as thick as 3/16-in. in a single pass with its 10- to 165-amp output. Every Diversion 165 box includes a 68-page TIG Welding for DummiesÒ book and a DVD on how to set up, operate and weld with the unit, along with some basic TIG welding tips.

Reduced Learning Curve

When developing the Diversion 165, Miller engineers borrowed from the proven technology used in the company’s industrial, inverter-based TIG products. As a result, the Diversion 165 starts with a positive, crisp snap time-and-time again. There’s no “arc stumbling” or “arc wander,” which can be a problem with some other TIG welders.

In addition, the Diversion 165 produces a focused arc cone, which provides better weld puddle control and greater directional control over heat input. Users can direct the arc precisely where they want it and keep the heat off areas they don’t want to weld. Finally, the Diversion 165 has a great low-end TIG arc in both the AC and DC welding modes, making it suitable for welding thin material and delicate work. Combined, these capabilities can enable users to begin producing quality welds in a shorter time.

Designed for Personal Users
While the Diversion 165 offers the arc starting and arc stability characteristics of Miller’s industrial TIG welders, Miller designed this machine strictly for personal users. The Diversion 165’s feature set, output and duty cycle are not recommended for professional or industrial fabrication. For these applications, Miller recommends its DynastyÒ, Maxstar® or SyncrowaveÒ series TIG welders.

Benefits of TIG

TIG welders offer the flexibility to weld almost any metal, including steel, stainless, chrome-moly and aluminum found on cars, boats, trailers and aircraft and the copper, bronze and brass seen in metal art and other applications. The only metal not typically suitable for TIG welding is cast iron.

The TIG process produces visually appealing weld beads with the classic “stacked dimes” look, and it can create high-quality structural welds suitable for ultra-critical applications, including motorsports and aerospace. The TIG process precisely controls heat input, allowing users to watch the weld puddle and make adjustments while welding. Users can weld on wafer-thin materials and weld with minimal distortion on surrounding metal.

Unlike MIG, Stick or flux cored welding, the TIG process does not produce sparks, spatter, smoke and slag.

Miller Electric Mfg. Co., headquartered in Appleton, Wis., is a leading worldwide manufacturer of Miller brand arc welding equipment and is a wholly owned subsidiary of Illinois Tool Works Inc. (NYSE: ITW).

For more information, visit Miller’s Web site at www.MillerWelds.com, call 1-800-4-A-Miller (800-426-4553), e-mail info@millerwelds.com, fax 877-327-8132, or write to Miller Electric Mfg. Co., P.O. Box 100, Lithonia, GA 30058