GTAW: Flat Welding

Position

credit: JarekJoepera/istock.com
Learning Objectives
• Describe the GTAW process.
• Determine the appropriate welding rod to use
when gas tungsten arc welding.
• Lay a bead on a plate using GTAW.
• Make a fillet weld on a lap joint in the flat
welding position.

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Learning Objectives (Cont.)
• Make a fillet weld on a T-joint in the flat
welding position.
• Weld a butt joint in the flat welding position.
• Describe the use of a backing when welding
aluminum using GTAW.
• Identify various weld defects.

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Introduction
• GTAW principles
– Strike arc between tungsten electrode and
base metal
– Arc melts small spot on base metal
– Filler metal may or may not be used
• Slower than SMAW, GMAW, and FCAW
• Shielding gas used

Lincoln Electric Company

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Preparing to Weld
• Assemble equipment
– Connect torch cables
– Connect source of shielding gas
• Check all connections
• Select current and other settings
• Choose, prepare, and install electrode
• Adjust shielding gas flow

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Typical GTAW Controls

Lincoln Electric Company

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GTAW Safety
• Use #10, #12, or #14 filter lens in welding helmet
• Wear proper clothes for welding
• Protect all body parts from welding arc
• Remove all combustible materials from area

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Welding Rod
• Usually similar to base metal
• Diameter is determined by size of weld
– Filler metal is added about once every 2 seconds
• Hold rod close to arc
– Keeps rod heated
– Protects tip with shielding gas

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Holding the GTAW Torch

Goodheart-Willcox Publisher

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Starting the Arc with a High-
Frequency Generator
• Hold electrode 1/8″
(3 mm) above base metal
– Press foot pedal or thumb switch
– Arc jumps gap
• Swinging motion

Goodheart-Willcox Publisher
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Touch-Starting the Arc
• Used only with DC welding
• Can contaminate the electrode
• Contamination produces unstable arc
– Makes welding more difficult
– Causes poor-quality weld

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Stopping the Arc
• Remove foot from pedal or turn off thumb switch
• Keep torch over end of weld area
– Post flow protects weld metal as it cools
• Use remote control device to reduce current near
end of weld
– Provides time to fill weld pool if necessary

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Travel and Work Angles for GTAW

Goodheart-Willcox Publisher
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Welding a Bead on Plate
• Start and stabilize arc
• Hold electrode 1/16″–1/8″ (1.5 mm–3 mm) above
work to form weld pool
• Move forward
• Move electrode to change current slightly
– More penetration or heat
– Avoid long, unstable arc to prevent porosity

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Moving the Electrode to Change
Current

Goodheart-Willcox Publisher
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Welding a Bead on Plate with Filler
Metal

Goodheart-Willcox Publisher
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Welding a Bead on Plate with Filler
Metal (Cont.)

Goodheart-Willcox Publisher
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Welding a Bead on Plate with Filler
Metal (Cont.)

Goodheart-Willcox Publisher
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Edge Weld without Welding Rod
• Base metal is melted
until the two metals flow
together

Goodheart-Willcox Publisher
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Fillet Weld without Welding Rod

Goodheart-Willcox Publisher
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Outside Corner Weld without
Welding Rod

Goodheart-Willcox Publisher
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Fillet Welding a Lap Joint
• Formed with or without filler metal
• Travel angle 15°–30°
• Work angle 45°
• Weld pool with C-shape

Goodheart-Willcox Publisher
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Inside Corner and T-Joints
• Tack weld about every
3″ (75 mm)
• C-shaped weld pool
• Travel angle 15°–30°
• Work angle 45°

Goodheart-Willcox Publisher
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Fillet Weld Size
• Add filler metal as needed to obtain size
• Weld should be as thick as metal being welded
• Measure lengths of legs

Goodheart-Willcox Publisher
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Angles for Welding Butt Joints

Goodheart-Willcox Publisher

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Welding Other Metals
• Stainless steel
– Much like mild steel
• Aluminum and magnesium
– Hot shortness—little strength when very hot
– Prevent sag by using stainless steel backing
• Titanium

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Weld Defects
• Defects • Other problems
– Porosity – Metal oxidation
– Undercutting – Unstable arc
– Lack of penetration
– Overlap
– Tungsten inclusions

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Porosity
• Cause
– Shielding gas does not protect weld area
• Corrections
– Check flow rate of shielding gas
– Check shielding gas connections for leaks
– Keep correct arc length

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Undercutting
• Cause
– Incorrect torch angle
• Corrections
– Use proper torch angles
– Add filler metal to fill any undercutting

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Lack of Penetration
• Cause
– Base metal is not heated properly
• Corrections
– Increase amperage
– Slow down travel speed
– Use correct torch angles

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Overlap
• Cause
– Large weld pool flows onto base metal and solidifies
• Corrections
– Keep weld pool proper size
– Use correct torch angles
– Do not add too much filler metal

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Tungsten Inclusion
• Causes
– Dipping electrode into weld pool
– Using too much welding current
– Using an electrode that is too small
• Corrections
– Use larger diameter electrode
– Reduce amount of welding current

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Oxidation
• Causes
– Oxygen combining with base metal
– Lack of shielding gas coverage
• Corrections
– Check shielding gas flow rate
– Use correct electrode extension and arc length
– Hold torch over end of weld during post flow

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Causes of Unstable Arc
• Contaminated electrode
• Electrode is too large in diameter
• Weld joint is too narrow
• Dirty base metal

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