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GTAW
• Fusion Welding Process
Gas Tungsten Arc Welding • Arc Between Non-Consumable Tungsten
Rod And Work
• Arc & Weld Pool Shielded By Argon
• Filler Wire Separately Added To Weld Pool
• Welding Torch & Tungsten Rod Cooled by
Flow OF Argon / Cooling Water

Equipment & Accessories

Shielding Gas Pressure Regulator
Flow Meter
• Inert Gas - Argon , Helium
Tungsten Rod
• Common Shielding Gas – Argon Argon Gas In
Cooling Water In Solenoid
• When Helium Is Used – Called “Heli – Arc” Welding Collet Valve Argon Cylinder

• When Argon Is Used – Called “Argon Arc” Welding Gas Lens

HF Unit &
Welding Cable & Cooling Water Cooling
• Inert Gas Prevents Contamination Of Molten Metal Ceramic Cup Water In Tube System
Cooling Water Out
• It Prevents Oxidation Of Tungsten Rod Argon Shielding
Arc
• It Ionizes Air Gap and Stabilizes Arc High Frequency
+ Connection
Work
• It Cools Welding Torch & Tungsten Rod
Pedal Switch Power Source
– +

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GTAW Equipment &

GTAW Accessories
• Power Source – Inverter, Thyrester,Rectifier,
Generator
• High Frequency Unit
• Water Cooling System
• Welding Torch- (Ceramic Cup, Tungsten Rod,
Collet, Gas-lens)
• Pedal Switch
• Argon Gas Cylinder
• Pressure Gauge, Regulator, Flow Meter
• Earthing Cable With Clamp

Types Of GTAW Power Source Power Source

• Inverter- DC
• Provides Electric Energy – Arc – Heat

• Thyrester – DC
• Drooping Characteristic

• Motor Generator – DC
• OCV – Appx. 80V,

• Rectifier – DC • Current Range 40 A to 300 A ( Capacity Of M/s)

• Transformer – AC (For Aluminium Welding Only) • Arc Voltage 18V to 26V

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High Frequency Unit

Characteristic Of GTAW
Power Source • Provides High Voltage Electric Energy With
Very high Frequency – 10000 Cycles / Sec.
Drooping – Constant Current
• Initiates low energy Arc / Spark & Ionize Air
V Gap.
V1
Vertical
V2
Curve • Electrically charges Air Gap For welding
Current to Jump Across the Tungsten Tip &
BM to Form An Arc.

A
A1 A2 • HF Gets Cut Off, Once Welding Arc Struck.

Water Cooling System

GTAW TORCH
• Provides Cooling Water To Welding Torch.

• Cools Tungsten Rod, Torch handle & Welding Torch Handle

Cap with collet For Cooling Water Outlet
Cable. Holding Tungsten
Argon Gas Inlet

• Cooling Water Returns through Flexible Tube Cooling Water Inlet Tube with cable
Which Carries welding cable within. Ceramic Cup

Tungsten Rod Argon Shielding Gas

Base Metal

Earthing Cable Arc

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Pedal Switch Argon Gas Cylinder- Pressure

Sequence
Regulator + Flow Meter

When M/c On • Cylinder Stores Argon

• Power source gets energized Cylinder Valve At High Pressure
• Pump starts pumping cooling water to torch
Pressure gauges
When Pedal Switch Pressed with tungsten rod held close to BM within 3mm
• Solenoid valve opens, Argon starts flowing • Regulator Regulates
• After 5 seconds of pre-purging, high Frequency current jumps from tungsten Flow Meter
rod generating sparks Cylinder Pressure to
• Immediately welding current makes arc across tungsten rod and work Flow Regulator Working Pressure
through the HF sparks.
• High frequency gets cut off from the system when welding arc is initiated and Pressure Regulator
welding is started.
When Pedal Released without lifting the torch Connection To Torch • Flow Meter Controls
1 Current gets cut off, Arc extinguishes, Gas flow continues as post purging. Flow Rate
2 Gas flow remains for few more seconds before it stops.
3 Torch to be lifted only after post purging stops Argon Cylinder

Shielding Gas Argon Gas Cylinder

• Argon - Purity 99.99% • Light Blue In Colour

• Impure Argon Results In Porosities

• Full Cylinder Pressure: 1800 psi ( 135 Kgs / Cm2 )
• Purity Verified by Fusing BQ CS plate
• Volume Of Argon In Full Cylinder: 7.3 M3
• Leakage of Argon in Torch Results in
Porosity. • Commercial Argon (99.99%) Cost: Rs 90/- Per M3

• Check Leakage by Closing the Ceramic

Cup With Thumb • High Purity Argon (99.999) Cost: Rs 110/- Per M3

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Back Purging Tools For GTAW

Purging Gas Commercial • Applicable to Single
Argon or Nitrogen Sided full penetration • Head Screen
• Prevents oxidation of
Filler Wire root pass from • Hand gloves
Welding Torch
opposite side of weld
• Essential for high • Chipping Hammer
alloy steels,
Purging Purging Gas In nonferrous metals • Wire Brush
Gas Out and alloys
Purging Root Pass
• Desirable For All • Spanner Set
chamber
Material

Tungsten Rod
Tungsten Rod Pulsed GTAW
• Non Consumable Electrode.
• Power Source Provides Two different Current
• Maintains Stable Arc Levels“Background” and “Peak”at regular
interval
• Tip to be Ground to a cone Shape of 60º • “Background” & “Peak” are above and below
to 30º angle
the Average Current
• Thoriated Tungsten for General
• Best Suitable for Full Penetration Open Root
Application, Zerconiated Tungsten for Pass Welding
Ground to
Aluminium Welding 50º ankle • Ideal for Root Pass by Automatic Machine
Welding
• Sizes :- 2, 2.4 & 3 mm Ø

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Pulsed GTAW - Automatic Filler Wire

• Added Separately to the weld pool.

• Compatible to base metal

• Used in cut length for manual welding.

• Used from layer wound spool for

automatic welding.

• Sizes :- 0.8, 1, 1.2, 1.6, 2, 2.4 & 3 mm

ASME Classification Of Filler Wire Dos & Don'ts In GTAW

Dos Don’ts
• Always Connect • Don’t Strike Arc With
SS Filler Wire: Electrode – Ve Electrode + Ve
SFA-5.9, ER 308, 308L, 316, 316L, 347, 309 • Keep Always Flow • Don’t strike Arc Without
LAS Filler Wire: Meter Vertical Argon Flow
SFA 5.28, ER 70S A1, ER 80S B2, ER90S D2, • Check & Confirm • Don’t Strike Arc By
Argon Purity touching Tungsten Rod
ER 80S Ni2
• Clean Groove & Filler • Don’t Touch Weld Pool
CS Filler Wire: wire With Acetone With Tungsten Rod
SFA- 5.18 , ER 70S2 • Grind Tungsten Tip to • Don’t Lift and break Arc
Point
C = 0.07%, Mn = 0.9% – 1.4%, Si = 0.4 – 0.7%, P = 0.025%, S = 0.035%

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Dos & Don'ts In GTAW Dos & Don'ts In GTAW

Dos Don’ts Dos Don’ts
• Break The Arc Only By • When Arc is Stopped • Provide Back Purging • Don’t Weld Single Sided
Pedal Switch Don’t Lift Torch For Single Sided Full Full Penetration Welds
• Lift The Torch only After immediately. Penetration Welds Without Back Purging
5 Sec Of Arc Break. • Don’t Weld With Blunt • Use N2 or Argon as • Don’t Use N2 As Back
• Ensure Pre Purging & Tungsten Rod Back Purging Gas For Purging Gas For Non
Post Purging of 5Sec • Don’t Weld With Argon CS & LAS Ferrous Alloys
• Ensure Argon Flow & Leaking Torch • Use Argon As Back • Don’t Empty Ag
Water Circulation To • Don’t Weld Without Purging Gas For SS & Cylinders Fully.
Torch Water Circulation Non Ferrous Alloys

Crack
Defects In GTAW
Cause Remedy
1. Cracks 2. Lack Of Fusion 1) Wrong Consumable 1) Use Right Filler Wire
3. Porosity 4. Undercut 2) Wrong Procedure 2) Qualify Procedure
3) Improper Preheat 3) Preheat Uniformly
5.Lack Of Penetration 6. Excess Penetration
4) Inadequate Thickness 4) Add More Filler Wire
7.Overlap 8. Suck Back In Root Pass in root Pass
9. Under Flush 10. Burn Through
11. Tungsten Inclusion 11.Stray Arcing crack

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Porosity
Lack Of Fusion Cause Remedy
1) Impure Argon Gas 1) Replace Argon Cylinder
Cause Remedy 2) Argon Leak Within Torch 2) Replace Leaking Torch
1) Inadequate Current 1) Use Right Current 3) Defective Filler Wire 3) Replace Filler Wire
2) Wrong Torch angle 2) Train /Qualify welder 4) Wet surface of BM 4) Clean & Warm BM
3) Improper bead placement 3) Train/Qualify Welder 5) Rusted / Pitted Filler wire 5) Clean Filler Wire
6) Improper Flow Of Argon 6) Provide Gas lens

Lack Of Fusion
Porosity . .

Lack Of Penetration*
Undercut
Cause Remedy
1) Excess Root Face 1) Reduce Root Face
Cause Remedy 2) Inadequate Root opening 2) Increase Root Opening
1) Excess Current 1) Reduce the Current 3) Over size Filler Wire 3) Reduce Filler Wire size
2) Excess Voltage 2) Reduce Arc length 4) Wrong Direction of Arc 4) Train / Qualify Welder
3) Improper Torch angle 3) Train & Qualify the Welder 5) Improper bead placement 5) Train / Qualify Welder
6) Improper weaving technique 6) Train & Qualify Welder

Under cut * Applicable to SSFPW

LOP

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Excess Penetration* Overlap

Cause Remedy
1)Excess root opening 1) Reduce root gap Cause Remedy
2) Excess Current 2) Reduce Current 1) Wrong Direction Of Arc 1) Train & Qualify Welder
3) Inadequate root face 3) Increase Root face 2) Inadequate Current 2) Increase Current
4) Excess Weaving 4) Train Welder 3) Excess Filler Wire 3) Reduce Filler Metal
5) Wrong Direction Of Arc 5) Train Welder
* Applicable to SSFPW Overlap

Excess Penetration

Suck Back* Under flush

Cause Remedy
Cause Remedy 1) Inadequate weld beads in 1) Weld some more beads
final layer in final layer
1) Excess weaving in root 1) Reduce weaving 2) Inadequate understanding on 2) Train / Qualify welder
weld reinforcement
2) Excess Current 2) Reduce Current
3) Wrong selection of filler wire 3) Train / Qualify Welder
3) Inadequate root face 3) Increase root face size
4) Wrong Electrode angle 4) Train / Qualify Welder
* Applicable to SSFPW in 4G, 3G & 2G
Under flush

Suck Back

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Burn through*
Tungsten Inclusion
Cause Remedy
Cause Remedy
1) Excess Current 1) Reduce the Current
1) Ineffective HF 1) Rectify HF Unit
2) Excess Root opening 2) Reduce root opening
2) Improper Starting of Arc 2) Never Touch Weld
3) Inadequate Root face 3) Increase root face
With Tungsten Rod
4) Improper weaving 4) Train / Qualify Welder
3) Tungsten Tip Comes in 3) Train / Qualify welder
Contact With Weld
*Applicable to root pass

Burn trough
Tungsten Inclusion

Stray Arcing
Cause Remedy
1) HF Not In Operation 1) Rectify HF Unit
2) Inadequate Skill of Welder 2) Train the Welder Thanks
Arc Strikes

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Pulsed GTAW - Automatic Pulsed GTAW - Automatic

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