Gas Tungsten Arc Welding

Objectives
Describe the gas tungsten arc welding process
List other terms used to describe it

What makes tungsten a good electrode

Eliminate tungsten erosion
Shape and clean a tungsten electrode
Grind a point on a tungsten electrode

Objectives (continued)
Remove a contaminated tungsten end
Melt the end of the tungsten electrode into the
desired shape
Compare water-cooled GTA welding torches to
air-cooled torches
The purpose of the three hoses connecting a
water-cooled torch to the welding machine

Objectives (continued)
Choose an appropriate nozzle
How to get an accurate reading on a flowmeter
Compare the three types of welding current used
for GTA welding
Shielding gases used in the GTA welding process

Objectives (continued)

Define preflow and postflow

Problems resulting from an incorrect gas flow rate
Properly set up a GTA welder
Establish a GTA welding arc

Introduction
The Gas Tungsten Arc Welding (GTAW) process
is sometimes referred to as a TIG or Heliarc
TIG is short for tungsten inert gas

An arc is established between a non-consumable

tungsten electrode (heating element) and the
base metal
The inert gas provides the needed arc
characteristics and protects the molten weld pool
When Argon became plentiful, the GTA process
became more common

Power Source Basics

Tungsten Electrodes

Tungsten
Tungsten has the following properties:

High tensile strength

Hardness
High melting temperature
High boiling temperature
Good electrical conductivity

Tungsten (continued)
Tungsten is the best choice for a non consumable
electrode
High melting temperature
Good electrical conductivity

As the tungsten electrode becomes hot the arc

between the electrode and the work stabilizes
But a clean and correctly ground tungsten is
needed

Because of the intense heat some erosion of the

electrode will occur

Figure 15-1 Some tungsten will erode and be transferred across the arc.

Tungsten (continued)
Ways to limit erosion:

Good mechanical and electrical contact

Use as low a current as possible
Use a water-cooled torch
Use as large a tungsten electrode as possible
Use DCEN current
Use as short an electrode extension as possible
Use the proper shape electrode
Use an alloyed tungsten electrode

Torch Build Out

Torch Build Out

Tungsten (continued)
The collet is the cone-shaped sleeve that holds
the electrode in the torch
Large-diameter electrodes conduct more current
The current-carrying capacity at DCEN is about
ten times greater than at DCEP
The preferred electrode shape impacts the
temperature and erosion of the tungsten
With alternating current, the tip is subjected to
more heat than with DCEN

Figure 15-3 The smooth surface of a centerless ground tungsten electrode. Courtesy of
Larry Jeffus.

Types of Tungsten Electrodes

Pure tungsten is an excellent nonconsumable
electrode
Pure tungsten can be improved by adding:

Cerium
Lanthanum
Thorium
Zirconium

Tungsten Electrodes

Table 15-1 Tungsten Electrode Types and Identification.

Shaping the Tungsten

To obtain the desired end shape:

Grinding (for MS and SS)

Breaking (not recommended due to cost)
Re melting the end (Aluminium welding)
Using chemical compound (doesnt work that well)

Grinding
Often used to clean a contaminated tungsten or
to point the end
Should have a fine, hard stone
A coarse grinding stone with result in more
tungsten breakage

Should be used for grinding tungsten only

Metal particles will quickly break free when the arc
is started, causing contamination

Figure 15-8 Correct way of holding a tungsten when grinding. Courtesy of Larry Jeffus.

Breaking and Remelting

Tungsten is hard but brittle
If struck sharply, it will break without bending
Try not to do this because of $$$$$$$$

Holding against a sharp corner and hitting results

in a square break
After breaking squarely, melt back the end

Chemical Cleaning and Pointing

Tungsten can be cleaned and pointed using one
of several compounds
Heated by shorting it against the work
Dipped in the compound
When the tungsten is removed, cooled, and
cleaned, the end will be tapered to a fine point
The chemical compound will dissolve the
tungsten, allowing the contamination to fall free

Pointing and Remelting

Tapered tungsten with a balled end is made by
first grinding or chemically pointing
The ball should be made large enough so that the
color of the end stays dull red and bright red
Increase ball size by applying more current
Surface tension pulls the molten tungsten up onto
the tapered end

Figure 15-14 Melting the tungsten end shape.

GTAW Equipment

GTA Welding Equipment

Cadillac Stick Welder

GTA welding torches are water- or air-cooled

Water-cooled GTA welding torch is more efficient
Water-cooled torch has three hoses connecting it
to the welding machine
Nozzle directs the shielding gas directly on the
welding zone
Flowmeter regulates the rate of gas flow

Figure 15-21 Schematic of a GTA welding setup with a water-cooled torch.

Types of Welding Current

DCEN concentrates about 2/3 of its welding heat
on the work
Max penetration
High Freq. start only

DCEP concentrates about 1/3 of its welding heat

on the work
Max cleaning action
2/3 of heat at tungsten primarily used for balling
tungsten for aluminium welding
High Freq. start only

Types of Welding Current

AC concentrates its heat at 50/50
Sign wave provides for DCRP (cleaning action)
and DCSP (penetration action)
Square wave technology allows for adjusting the
cleaning or penetration cycle.
High Freq. is on Continuous so there is equal
firing of both sides of sign wave.
DC Component will take place if there is no High
Freq.

Figure 15-29 Electrons collect under the oxide layer during the DCEP portion of the cycle.

Figure 15-30 Sine wave of alternating current at 60 cycle.

Shielding Gas

Shielding Gases
Shielding gases used for GTA welding process:
Argon (Ar)
Helium (He)
Or a mixture of two or more gases

Shielding Gases (continued)

Argon effectively shields welds in deep grooves in
flat positions
Helium offers the advantage of deeper
penetration

Shielding Gases (continued)

Hot start allows a surge of welding current
Preflow is the time gas flows to clear out air in the
nozzle
Some machines do not have preflow

Postflow is the time the gas continues flowing

after the welding current has stopped

Shielding Gases (continued)

Ionization Potential
Amount of voltage needed to kick start the arc

The ionization potential, or ionization energy, of a gas atom is the energy required to strip it of an electron. That is
why a shielding gas such as helium, with only 2 electrons in its outer shell, requires more energy (higher voltage
parameters) for welding. The ionization potential of a shielding gas also establishes how easily an arc will initiate and
stabilize. A low ionization potential means the arc will start relatively easy and stabilize quite well. A high ionization
potential has difficulty initiating and may have difficulty keeping the arc stable.

Argon
15.7 electron volts

Helium
24.4 electron volts
More penetration

Figure 15-35 Too steep an angle between the torch and work may draw in air.

Remote Controls
Foot or Finger

Remote Controls
Can be used to:

Start the weld

Increase the current
Decrease the current
Stop the weld

Remote can be foot-operated or hand-operated

device

Welding Techniques

Objectives
Applications using the gas tungsten arc welding
process
Effects on the weld of varying torch angles
Why and how the filler rod is kept inside the
protective zone of the shielding gas
How tungsten contamination occurs and what to
do
Causes of change in welding amperage
Correct settings for the minimum and maximum
welding current

Objectives (continued)
Types and sizes of tungsten and metal
Factors affecting gas preflow and postflow times
Minimum and maximum gas flow settings:
Nozzle size
Tungsten size
Amperage setting

Characteristics of low carbon and mild steels,

stainless steel, and aluminum
Metal preparation for GTA welding
Make GTA welds in all positions

Introduction
Gas tungsten arc is also called GTA welding
GTA welding can be used to for nearly all types
and thicknesses of metal
GTA welding is fluxless, slagless, and smokeless
Welders have fine control of the welding process
GTA welding is ideal for close-tolerance welds
Some GTA welds make the critical root pass
GTA used when appearance is important

Introduction (continued)
Setup of GTA equipment affects weld quality
Charts give correct settings

Field conditions affect the variables in the charts

Experiments designed to evaluate the
appearance of a weld
After welding in the lab, troubleshooting field
welding problems is easier
To make a weld is good: to solve a welding
problem is better

Torch Angle
As close to perpendicular as possible
May be angled 0-15 degrees from perpendicular
for better visibility
As the gas flows out it forms a protective zone
around the weld
Too much tilt distorts protective shielding gas
zone

Figure 16-5 Filler being remelted as the weld is continued. Courtesy of Larry Jeffus.

Torch Angle (continued)

Velocity of shielding gas affects protective zone
Low-pressure area develops behind the cup
when velocity increases
Sharper angle and higher flow rate increases
contamination

Filler Rod Manipulation

Filler rod must be kept inside the protective zone
If filler rod is removed from the gas protection, it
oxidizes rapidly
Oxide is added to the molten weld pool

When a weld is temporarily stopped, the

shielding gas must be kept flowing

Filler Rod Manipulation (continued)

If the rod tip becomes oxidized, if should be cut
off before restarting
The rod should enter the shielding gas as close
to the base metal as possible
An angle less than 15 degrees prevents air from
being pulled in the welding zone

Figure 16-2 The hot filler rod end is well within the protective gas envelope. Courtesy of
Larry Jeffus.

Figure 16-7 Too much filler rod angle has caused oxides to be formed on the filler rod
end. Courtesy of Larry Jeffus.

Tungsten Contamination
Most frequent problem is tungsten
contamination
Tungsten becomes contaminated if it touches:
Molten weld pool
Filler metal

Surface tension pulls the contamination up onto

the hot tungsten
Extreme heat causes some of the metal to
vaporize and form a large oxide layer

Tungsten Contamination (continued)

Contamination caused by the tungsten touching
the molten pool or filler metal forms a weak weld
The weld and tungsten must be cleaned before
any more welding can be done
Tiny tungsten particles will show up if the weld is
x-rayed
Contamination can be knocked off quickly by
flipping the torch head
This procedure should never be used with heavy
contamination or in the field

Figure 16-8 Contaminated tungsten. Courtesy of Larry Jeffus.

Current Setting
Amperage on the machine's control is the same
at the arc when:

Power to the machine is exactly correct

Lead length is very short
All cable connections are perfect
Arc length is exactly right
Remote current control is in the full on position

Figure 16-10 Melting first occurring. Courtesy of Larry Jeffus.

Figure 16-12 Oxides forming due to inadequate gas shielding. Courtesy of Larry Jeffus.

Gas Flow
Gas preflow and postflow times depend upon:

Wind or draft speed

Tungsten size used
Amperage
Joint design
Welding position
Type of metal welded

Maximum flow rates must never be exceeded

Air can be sucked into the weld zone

Practice Welds
Practice welds are grouped according to the
weld position and type of joint
Mild steel is inexpensive and requires the least
amount of cleaning
With aluminum, cleanliness is a critical factor
Try each weld with each metal to determine
which metal will be easier to master

Low Carbon and Mild Steels

Low carbon and mild steel are two basic steel
classifications
Small pockets of primary carbon dioxide gas
become trapped
Porosity most likely when not using a filler metal
Most filler metals have some alloys, called
deoxidizers

Stainless Steel
Setup and manipulation are nearly the same as
for low carbon and mild steels
Most welds on stainless steels show effects of
contamination
Most common problem is the bead color after
the weld
Using a low arc current with faster travel speeds
is important

Aluminum
Molten aluminum weld pool has high surface
tension
Preheat the base metal in thick sections
Preheat temperature is around 300 Fahrenheit
Cleaning and keeping the metal clean is time
consuming
Aluminum rapidly oxidizes at welding
temperatures

Metal Preparation
Base and filler metals must be thoroughly
cleaned
Contamination will be deposited into the weld
Oxides, oil, and dirt are the most common
Contaminants can be removed mechanically or
chemically

Figure 16-15 Aluminum filler being correctly added to the molten weld pool. Courtesy of
Larry Jeffus.

Figure 16-16 Filler rod being melted before it is added to the molten pool. Courtesy of
Larry Jeffus.

Figure 16-18 Surfacing weld. Courtesy of Larry Jeffus.

Figure 16-20 Establish a molten weld pool and dip the filler rod into it. Courtesy of Larry
Jeffus.

Figure 16-21 Note the difference in the weld produced when different size filler rods are
used. Courtesy of Larry Jeffus.

Figure 16-22 Move the electrode back as the filler rod is added. Courtesy of Larry Jeffus.

Figure 16-34 Be sure both the top and bottom pieces are melted. Courtesy of Larry
Jeffus.

Figure 16-35 Oxides form during tack welding. Courtesy of Larry Jeffus.

Figure 16-36 A notch indicates the root was not properly melted and fused. Courtesy of
Larry Jeffus.

Figure 16-37 Watch the leading edge of the molten weld pool. Courtesy of Larry Jeffus.

Summary
Positioning yourself to control the electrode filler
metal and to see the joint is critical
Experienced welders realize they need to see
only the leading edge of the weld pool
Good idea to gradually reduce your need for
seeing 100% of the weld pool
Increasing this skill is significant advantage in the
field

Welding in the field may have to be done out of

position