Everlast PowerTIG 400EXT – 400 Amp Industrial AC/DC TIG & DC Stick Welder

Maximum TIG power for heavy aluminum, thick plate, production welding, and demanding industrial work.
The Everlast PowerTIG 400EXT is the most powerful machine in the PowerTIG EXT lineup, delivering up to 400 amps of AC/DC TIG output and up to 315 amps of Stick welding power. Built for shops that regularly weld thick aluminum, heavy steel, large fabrications, and production assemblies, it combines brute-force output with the fine arc control expected from a professional digital TIG platform.

Despite its high output, the PowerTIG 400EXT still provides low-amperage control down to 5 amps DC and 10 amps AC, making it capable of handling both heavy weldments and precision work. Advanced AC Pulse, four selectable AC waveforms, digital microprocessor control, and professional Stick settings give experienced operators the flexibility to tackle a wide range of industrial applications.

Why Professionals Choose the PowerTIG 400EXT

• 400 Amp TIG Output: Serious power for heavy aluminum, thick plate, large weldments, and industrial fabrication.
• 315 Amp Stick Output: Handles demanding repair and fabrication work with electrodes up to 1/4".
• Advanced AC Pulse: Improves penetration on thick aluminum while helping reduce heat input on thinner material.
• Four AC Waveforms: Fine-tune arc feel, cleaning action, penetration, and puddle control.
• Low-Amp Precision: Operates down to 5 amps DC and 10 amps AC despite its high output.
• Single- or Three-Phase Input: Designed for 240V shop power in demanding industrial environments.

Advanced AC Waveform Control

• Advanced Square Wave: Focused arc with strong penetration and fast puddle response.
• Soft Square Wave: Smoother arc characteristics with a more forgiving feel.
• Triangular Wave: Lower average heat input for thinner aluminum and reduced distortion.
• Sine Wave: Smooth, traditional transformer-style arc characteristics.

Key Features

• Up to 400 amps of AC/DC TIG output
• Up to 315 amps of DC Stick output
• Digital microprocessor control
• Heavy-duty IGBT power modules
• Low-amperage operation down to 5 amps DC and 10 amps AC
• 2T, 4T, foot pedal, and torch-amptrol operating modes
• Four selectable AC waveforms
• Adjustable AC frequency and AC balance
• Pulse up to 500 Hz in DC mode
• Pulse up to 250 Hz in AC mode
• Advanced AC Pulse up to 10 Hz
• Easy Start modes for faster AC and DC setup
• Electronic HV Start for smoother starts and reduced maintenance
• Lift Start capability
• Spot-weld timer for repeatable tacking and sheet-metal work
• Adjustable Stick Arc Force
• Adjustable Stick Hot Start time and intensity
• VRD safety function for Stick welding applications
• E6010 and cellulose-electrode capability
• Fan-On-Demand cooling
• Rear 240V receptacle for compatible water cooler
• Simplified menu layout with no hidden setup routines

Duty Cycle & Output

• TIG Output: Up to 400 amps
• TIG Duty Cycle: 35% at 400 amps
• Stick Output: Up to 315 amps
• Stick Duty Cycle: 35% at 315 amps

The high-output cooling system is designed to support demanding shop use and help the machine maintain strong performance during heavy welding cycles.

What’s Included

• 18 Series Water-Cooled TIG Torch with 12.5' Cable, 35 Series DINSE Connector, and Torch Switch
• 26 Series Air-Cooled TIG Torch with 12.5' Cable, 35 Series DINSE Connector, and Torch Switch
• Stick Electrode Holder with 10' Cable and 35 Series DINSE Connector
• Heavy-Duty Ground Clamp with 10' Cable and 35 Series DINSE Connector
• Compact Foot Pedal
• Everlast Billet-Brass Regulator with Gas Hose
• Starter TIG Consumable Kit
• 6' Power Input Cable

Note: Tungsten electrodes, water cooler, power plug, and welding cart are not included.

Ideal Applications

• Heavy aluminum fabrication
• Production welding
• Industrial manufacturing
• Large weldments and thick plate
• Shipyard fabrication
• Pipeline and pressure work
• Aerospace and aircraft fabrication
• Motorsports and off-road fabrication
• Heavy equipment repair
• Farm and ranch maintenance
• Industrial maintenance
• Prototype development

Recommended Materials

• Aluminum
• Steel
• Stainless steel
• Chrome-moly
• Titanium
• Copper
• Nickel alloys
• Most weldable metals

TIG Welding Capacity

• Steel, Single Pass: Up to approximately 3/4"
• Steel, Multi-Pass: Up to approximately 1"+
• Aluminum, Single Pass: Up to approximately 3/4"
• Aluminum with Advanced AC Pulse: More than 1" may be possible in certain applications
• Aluminum, Multi-Pass: Up to approximately 1"+
• Minimum Steel Thickness: Approximately .005"
• Minimum Aluminum Thickness: Approximately .010"

TIG capacity figures are based on accepted industry practices for quality single- and multi-pass welding. Advanced AC Pulse may extend practical thickness capability when properly adjusted. Actual performance depends on joint design, material condition, shielding gas, tungsten size, operator technique, and application requirements.

Stick Welding Capacity

• Minimum Electrode Diameter: 1/16"
• Maximum Electrode Diameter: Up to approximately 1/4"
• Electrode Capability: Includes E6010 and other common cellulose-based electrodes

Maximum electrode diameter depends on electrode classification, manufacturer recommendations, welding position, and application.

Power Requirements

• 240V single-phase or three-phase input
• Power plug must be supplied and installed by the customer
• Use only properly sized electrical service and protection
• Consult a qualified electrician before installation

Generator Requirements

• Use only generators certified by the manufacturer as producing clean power
• Total harmonic distortion must be less than 5%
• Minimum recommended generator capacity: 22,000 surge watts for 240V single-phase operation

Using an undersized generator or one that does not meet clean-power requirements may damage the machine and affect warranty coverage.

Important Operating Notes

• This machine is not designed for carbon-arc gouging.
• Using the PowerTIG 400EXT for carbon-arc gouging may void the warranty.
• A compatible water cooler is strongly recommended when operating at high output with the included water-cooled TIG torch.

Who Is the PowerTIG 400EXT Best For?

The PowerTIG 400EXT is intended for professional shops that regularly encounter thick aluminum, heavy steel, large assemblies, and high-output production welding. It is especially well suited for industrial fabrication, shipyards, aerospace, heavy equipment, motorsports, and maintenance departments that need more power than a typical 200- or 250-amp TIG welder can provide.

Frequently Asked Questions

Can the PowerTIG 400EXT weld aluminum?
Yes. It provides full AC TIG capability with four selectable waveforms, adjustable AC frequency and balance, and Advanced AC Pulse for improved performance on thick aluminum.

How much TIG output does it provide?
The machine delivers up to 400 amps of TIG output with a 35% duty cycle at maximum amperage.

Can it Stick weld?
Yes. It provides up to 315 amps of Stick output and supports electrodes up to approximately 1/4", including E6010 and other cellulose-based rods.

Does it include a water-cooled torch?
Yes. It includes both an 18 Series water-cooled TIG torch and a 26 Series air-cooled TIG torch. The required water cooler is sold separately.

Can it handle thin material?
Yes. Despite its high output, the machine can operate down to 5 amps DC and 10 amps AC for more delicate welding work.

Can I run it from a generator?
Yes, but the generator must produce clean power with less than 5% THD and provide at least 22,000 surge watts for 240V single-phase operation.

Can it be used for carbon-arc gouging?
No. The PowerTIG 400EXT is not designed for carbon-arc gouging, and using it for that process may void the warranty.