Unit 7 Shielded Gas Arc Welding: Objectives

J3103/7/1
SHIELDED GAS ARC WELDING
UNIT 7 SHIELDED GAS ARC WELDING
OBJECTIVES
General Objective: To understand the principles of shielded

gas arc welding i.e. TIG and MIG welding.
Specific Objectives : At the end of the unit you will be able

to :
 Identify the principles of shielded gas arc

welding i.e. TIG and MIG welding.
 Elaborate on the TIG and MIG welding

principles, welding procedures, welding
machines, gas, etc.
 State the advantages and disadvantages of

TIG and MIG compared to manual arc
welding.
 State the weaknesses of TIG and MIG

welding and how to prevent them.
.
J3103/7/2
INPUT
7.0. INTRODUCTION
The objective of welding is to produce a welding joint that

contains the same mechanical properties as the base metal. The
objective can be achieved if the molten metal is free from atmospheric
air. If not, nitrogen and oxygen gases in the atmosphere will be
absorbed by the melting pool. The welding produced will have small
pore that will weaken the weld.
To prevent the welding, molten metal and the end of the filler
rode and electrodes from atmospheric air pollution before the molten
metal become solid inert gas is blown out from the welding point.
These gases will cover the welding pools, the filler rod points and
electrode tips to avoid oxidation.
7.1. TUNGSTEN INERT GAS (TIG)
The welding of aluminium and magnesium alloys by the oxy-

acetylene and manual metal arc processes is limited by the necessity
to use a corrosive flux. The gas shielded, tungsten arc process enables
these metals and a wide range of ferrous alloys to be welded without
the use of a flux. The choice of the either a.c. or d.c. depends upon the
J3103/7/3
metal to be welded. For metals having refractory surface oxides such

as aluminium and its alloys, magnesium alloys and aluminium bronze,
a.c. is used whilst d.c. is used for
carbon and alloy steels, heat-resistant and stainless steels, cooper and
its alloys, nickel and its alloys, titanium, zirconium and silver.
The arc burns between a tungsten electrode and the work piece
within a shield of the inert gas argon, which excludes the atmosphere
and prevents contamination of electrode and molten metal. The hot
tungsten arc ionizes argon atoms within the shield to form a gas
plasma consisting of almost equal numbers of free electrons and
positive ions. Unlike the electrode in the manual metal arc process,
the tungsten is not transferred to the work and evaporates very slowly,
being classed as ‘non-consumable’. Small amount of other elements
are added to the tungsten to improve electron emission.
Gas flow
Torch
Water outlet
Welding
machine
Work piece
Water inlet
J3103/7/4
Figure 7.1. TIG welding

equipment
Electrode
(tungsten)
Inert/noble
gas
Filler rode
Shielded gas
arc
Direction of travel
80 – 90o
20 – 30o
Melting pool
Work piece
Figure 7.2. TIG in progress. The tungsten does not

melt into the puddle for filler. This is a nonconsumable
electrode.
7.1.1. Preparation of Metal.
Gas tungsten-arc processes must start with clean metal

which has the proper joint design i.e., V, U, or J. Mechanical and
chemical cleaning are often necessary to prepare the base metal.
The edges of the joint should be shaped to permit adequate
fusion and penetration. It is common practice to reduce or bevel
the adjoining edges to 1.6 mm thickness.
A strip (backup bar) to support the back side of the base
metal should be used when needed. This is especially helpful on
J3103/7/5
aluminium since it aids in shielding. The backup bar may be

removed after welding.
7.1.2. Joint Fit.
Good joints make it easier to obtain a good weld. In

production work, carefully fitted joints can help save money and
can help the welding operator develop standardized welding
techniques. Root opening (distance apart) and angle of bevel are
two major factors requiring close tolerance when fitting joints.
7.1.3. Welding Machine.
Gas tungsten-arc welding requires a conventional welding

machine, with the following accessories:
1. Torch, lead cable, and hoses.
2. Inert gas supply and flow meter for measuring
amount of shielding gas.
3. Water cooling system for water-cooled torches.
Air-cooled torches are limited to 150 ampere
capacity.
4. High-frequency spark unit attached to the output
leads of the power supply (to start and stabilize
arc).
The finished weld will be greatly affected by type of current

and polarity. For example, aluminium is welded with alternating
current plus superimposed high-frequency current (ACHF).
Stainless steel is welded with direct current straight polarity
J3103/7/6
(DCSP). Improper electrical connections will cause (a) the

electrode to overheat, (b) poor penetration, or (c) insufficient
cleaning effect upon the base metal.
Current selection must be made with care. When an
electrode is connected to the negative terminal (DCSP), electrons
pass through the arc to bombard the base plate (Fig. 7.3).
Welding Electrode
machine
Direction of electron
travel
Positive surface
particles travel
Work piece
Deep penetration
Figure 7.3 Power supply with direct current

straight polarity
This causes nearly 70% of the arc heat to accumulate in

the base metal to assist fusion and penetration. When the
electrode is made positive (DCRP), a cleaning effect is created on
the surface of the base plate (Fig. 7.4).
Welding
Electrode
machine
Direction of electron
Positive surface travel
particles travel
Work piece
Shallow penetration
Figure 7.4 Power supply with direct current

reverse polarity
J3103/7/7
In welding aluminium this method is used to remove

surface oxidation. While an electrode positive connection
furnishes a cleaning effect, it also heats the tungsten electrode.
The electrode may get hot
enough to melt, transfer to the weld pool, and contaminate the

base metal. When this happens, the electrode must be removed,
its end broken off, and it must be ground to shape.
Alternating current offers the advantages of both direct
current straight polarity (DCSP) and direct current reverse
polarity (DCRP). Gas tungsten-arc welding of aluminium and
magnesium requires an AC power supply (Fig. 7.5).
Gas tungsten-arc welding is not recommended for metal
more than 20 mm thick. Welds have been completed on 25 mm
thick plate but require a great deal of time and, consequently,
are expensive. Most applications are less than 12 mm thick, and
require less than 500 amperes of current.
Welding Electrode
machine
Surface
particles lifted Electron flow
Work piece
Medium penetration
Figure 7.5 Alternating current power

supply
J3103/7/8
7.1.4. Welding Torch.
The welding torch has a round collet which compresses to

hold the electrode and a nozzle to control the gas (Fig. 7.2).
Water-cooled torches are used when current values exceed 150
amperes. Maintenance of either torch is more time consuming
than with the metal-arc process. Careful selection of nozzle size,
proper shaping of the working end of the electrode and correct
extension of electrode beyond nozzle are important. Nozzle size
influences the flow of gas. End shape of electrode and extension
of electrode beyond nozzle control the stability of the arc.
Further, it is important that electrode diameter match current
value (Table 7.1). If the current is too high for the diameter of an
electrode, the life of the electrode will be reduced. When the
current is too low for a given electrode diameter, the arc will not
be stable.
Table 7.1. Selection of nozzle size and electrode size for gas
tungsten-arc welding
Electrode Nozzle or WELDING CURRENT IN AMPERES

ACHF DCSP DCRP
Size Cup Sizes
Pure Thoriated Pure or Pure or
(Diameter,
Tungsten Tungsten Thoriated Thoriated
Inches)
0.020 4,5 5-15 5-20 5-20 *
0.040 4,5 10-60 15-80 15-80 *
J3103/7/9
1/16 4-6 50-100 70-150 70-150 10-20

3/32 5-7 100-160 140-235 150-250 15-30
1/8 6-8 150-210 225-325 250-400 25-40
*Not applicable.
The end of the electrode should remain bright, as if it was

polished. On some metals, such as aluminium and magnesium,
the end is contaminated when starting or by touching the base
plate. Contamination can be burned off by welding on a scrap
plate of metal, or it can be removed by grinding (Fig. 7.6). The
electrode should be adjusted to extend beyond the nozzle a
distance equal to the electrode diameter (Fig. 7.7)
15o 30o
45o
Grind here
DCSP DCRP AC
Figure 7.6 Electrode shapes for gas shielded tungsten-arc

welding
3/8” max
Electrode diameter
Figure 7.7. Adjustment of electrode

from nozzle
J3103/7/10
7.1.5. Shielding Gas.
Gas used with this process produces an atmosphere free

from contamination and also provides a path for arc transfer. The
path creates an environment that helps stabilize the arc. The gas
and arc activity also perform a cleansing action on the base
metal. Both argon and helium are generally used for this process
but argon is preferred because it is cheaper and provides a
smoother arc. Helium, however, helps produce deeper
penetration (Table 7-2).
7.1.6. Filler Metal.
Filler metals are selected to meet or exceed the tensile

strength, ductility, and corrosion resistance of the base metal.
The usual practice is to select a filler metal having a composition
similar to that of the base metal. For most efficient application,
select clean filler metals of proper diameter; the larger the
diameter of the filler metal, the more heat is lost from the weld
pool.
J3103/7/11
Metal Shielding Gas Remarks

Table 7.2 Selection of gases for manual application of
Aluminium Argon Easy starting
tungsten-arc welding. Good cleaning action.
Helium Faster and more penetration.
Argon-10% helium Increase in penetration over pure
argon.
Stainless Argon Better control of penetration (16 gauge
steel and thinner).
Argon-helium Higher welding speeds.
mixtures
Copper and Argon Easy to control penetration and weld
nickel contour on sheet metal.
Argon-helium Increases heat into base metal.
Helium Highest welding speed.
7.2. TIG WELDING TECHNIQUES
After the base metal has been properly cleaned and clamped or
tacked together, welding can be started. On aluminium, the arc is
usually started by bringing the electrode near the base metal at a
distance of about one electrode diameter so that a high-frequency
spark jumps across the gap and starts the flow of welding current.
Steel, copper alloys, nickel alloys, and stainless steel may be touched
with the electrode without contamination to start the arc. Once
started, the arc is held stationary until a liquid pool appears. Filler rod
can be added to the weld pool as required (Fig. 7.8). Highest current
values and minimum gas flow should be used to produce clean, sound
welds of desired penetration (Table 7-3).
J3103/7/12
Table 7.3 Operating data for TIG
Material Aluminium Stainless Magnesium Deoxidized

Steel Copper
Type of Current ACHF DCSP ACHF DCSP
1.6mm electrode
Current: 60-80 80-100 60 110-140
Argon: 15 cfh 11 cfh 13 cfh 15 cfh
Passes: 1 1 1 1
3.2mm electrode
Current: 125-145 120-140 115 175-225
Passes: 1 1 1 1
4.7mm electrode
Current: 190-220 200-250 120-175 250-300
Passes: 1 1 1,2 1 at 257.4*
*Preheat to temperature indicated.
The shielded gas is pure argon and pre-heating is required for

drying only to produce welds of the highest quality. All surfaces and
welding wire should be degreased and the area near the joint and the
welding wire should be stainless steel wire brushed or scrape to
remove oxide and each run brushed before the next is laid.
The angles of torch and filler rod are shown in Fig. 7.8. After
switching on the gas, water, welding current and HF unit, the arc is
struck by bringing the tungsten electrode near the work (without
touching down). The HF sparks jump the gap and the welding current
flows. Arc length should be about 3 mm. Practice starting by laying
the holder on its side and bringing it to the vertical position, but using
the ceramic shield as a fulcrum can lead to damage to the holder and
ceramic shield. The arc is held in one
J3103/7/13
position on the plate until a molten pool is obtained and welding is

commenced, proceeding from right to left, the rod being fed into the
forward edge of the molten pool and always kept within the gas shield.
It must not be allowed to touch the electrode or contamination occurs.
A black appearance on the weld metal indicates insufficient argon
supply.
15o
Direction of
30o travel
Figure 7.8. Example of TIG
The flow rate should be checked and the line inspected for leaks.
A brown film on the weld metal indicates presence of oxygen in the
argon while a chalky white appearance of the weld metal accompanied
by difficulty in controlling the weld indicates excessive current and
overheating. The weld continues with the edge of the portion sinking
through, clearly visible, and the amount of the sinking which
determines the size of the penetration bead is controlled by the
welding rate.
7.3. METAL INERT GAS (MIG)
It is convenient to consider, under this heading, those

applications which involve shielding the arc with argon, carbon dioxide
J3103/7/14
(CO2) and mixtures of argon with oxygen and/or CO 2, since the power
source and
equipment is essentially similar except for gas supply. With the

tungsten inert gas shielded arc welding process, inclusions of tungsten
become troublesome with currents above 300 A. The MIG process
does not suffer from these advantages and larger welding current
giving greater deposition rates can be achieved. The process is
suitable for welding aluminium, magnesium alloys, plain and low-alloy
steels, stainless and heat-resistant steel, copper and bronze, the
variation being filler wire type of gas shielding the arc.
The consumable electrode of bare wire is carried on the spool
and is fed to a maually operated or fully automatic gun through an
outer flexible cable by motor-driven rollers of adjustable speed, and
rate of burn-off of the electrode wire must be balance by rate of wire
feed. Wire feed rate determines the current used.
In addition, a shielding gas or gas mixture is fed to the gun
together with welding current supply, cooling water flow and return (if
the gun is water cooled) and a control cable from gun switch to control
contractors. A d.c. power supply is required with the wire electrode
connected to the positive pole ( Fig. 7.9).
Arc welding Gas flow
power supply meter
Spool of Inert gas

Welding
electrode cylinder
power
cable wire
Electrode
feed Contactor lead,welding
rools current,electrode, and
inert gasto welding gun
Contactor Control head

cable forelectrode feed
Ground and gas supply
cable
Figure 7.9 . MIG welding

equipment
J3103/7/15
During this process an electric arc is used to heat the weld zone.
The electrode is fed into the weld pool at a controlled rate and the arc
is shielded by a protective gas such as argon, helium, or carbon dioxide
(Fig. 7.9). Gas metal-arc welding can be either the short-circuiting
process or the spray-arc process (Fig. 7.10).
Inert/noble gas
Shielded gas
Arc
Melting pool
Work piece
Figure 7.10. MIG in

progress
The short-circuiting arc process (short arc) operates at low
currents and voltages. For example, 18-gauge sheet metal can be
welded at 45 amps and 12 volts.
Work piece
Figure 7.11. Mechanics of the short circuiting transfer

process as shown between the electrode and work piece.
Electrode dips into pool an average of 90 times a second
In contrast, the spray-arc process uses high currents and
voltages, e.g., Arc action is illustrated in Fig. 7.12. This results in high
heat input to the weld area, making possible deposition rates of more
J3103/7/16
than 0.4 lb per minute. (The deposition rate is the weight of filler
metal melted into the weld zone
per unit of time.) Most applications of the spray-arc process are in

thick metal fabrications, e.g., in heavy road-building machinery, ship
construction, and beams for bridges.
Electrode maintains steady arc length
Work piece
Figure 7.12. Mechanics of the spray-arc

transfer process as shown between the
electrode and work
All metal inert-gas (MIG) welding is classified as semi-automatic,

since the electrode feeds into the weld according to a preset
adjustment. After making an initial adjustment, the welding operator
merely moves the gun along the joint. For effective applications, the
welding operator needs information concerning power requirements,
welding gun, selection of shielding gas, type of filler metal, and job
procedures.
7.3.1. Power Requirements.
Conventional power supplies used for shielded metal-arc

welding are not satisfactory. A welding machine designed for the
MIG process is called a constant potential power source; it
J3103/7/17
produces a constant voltage and also permits the operator to

adjust electrode feed
rates. The adjustments on the power supply are voltage, slope
(limits current), and wire feed rate. Welding current is established
by
selecting a wire feed rate. Slope adjustment to limit current is

not a problem with spray-arc type transfer. However, in short-
circuiting arc processes, limitations on short-circuit current are
essential to prevent excessive spatter.
The electrode feed mechanism, an important part of the
welding machine, consists of a storage reel for electrode wire
and a power drive which feeds the electrode into the weld at a
controlled rate.
Table 7.4 Shielding mixtures for MIG
Metal Shielding Gas Remarks

Aluminium and copper Argon + helium High heat input
20-80% mixture Minimum of porosity
Copper Argon + nitrogen Good heat input on
25-30% mixture copper
Carbon steels Argon + oxygen Stabilizes arc
Low alloy steels 3-5% mixture Reduces spatter
Causes weld metal to flow
Eliminates undercut
May require electrode to
contain deoxidizers
Low alloy steels Mixture of argon, Increases toughness of
helium and carbon weld deposit
dioxide
J3103/7/18
7.3.2. Selection of Gas.
The primary purpose of the inert gas is to shield the weld

crater from contamination. Shielding gas may also affect (1) the
transfer of
metal across the arc, (2) fusion and penetration, (3) the shape of
weld deposit, (4) the speed of completing the weld, (5) the ability
of filler metal to flow over the surface without undercutting, and
(6) the cost of the finished weld.
No single inert gas is satisfactory for all welding conditions.
Some specific jobs are more efficiently welded with a mixture of
gases.
For example, low alloy steels are welded with a mixture of argon,
helium, and carbon dioxide (Table 7.4).
7.3.3. Filler Metal.
Electrodes used for filler metal with the MIG process are
much smaller in diameter than those used with the metal-arc
process. Sizes may range from 0.4 mm to 5.5 mm in diameter.
Small diameter electrodes require high feed rates, from 100 to
1,400 inches per minute. The composition of the electrode
usually matches that of the base metal, but for welding
high-strength alloys, the composition of the electrode may vary
widely from that of the base metal.
J3103/7/19
For example, an aluminium-zinc-magnesium alloy (7039) is

welded with an aluminium-magnesium alloy (5356).
7.4. JOB PROCEDURES
High-quality welds are obtained by controlling process variables

which include current, voltage, travel speed, electrode extension,
cleanliness, and type of joint.
7.4.1. Current.
Welding current varies with the melting rate of the

electrode. Extreme values of current tend to promote defects,
but a high current (1.1 mm. electrode at 220 amp) reduces the
drop size of the transfer, improves arc stability, and improves
penetration.
7.4.2. Voltage.
With the MIG welding process, the voltage control

determines the arc length. The higher the voltage setting, the
longer the arc. A desirable voltage range to establish a short arc
is 19-22 volts; defects are more likely to occur outside this range
(Fig. 7.14).
Severity of defect (Increase)
J3103/7/20
Severity of defect (Increase)

Curve representing
Curve representing porosity
undercutting
Voltage Voltage
Fig. 7.13. Defects related to voltage settings.
Position of welding will determine voltage needed. For example,

a higher voltage is more desirable for flat-position welding than for
vertical or overhead welding. Table 7-5 indicates typical voltage values.
Metal
Table Argon
7-5 Typical Helium
arc voltage for Ar-O Mixture
MIG 2using CO2
drop transfer
and 1/16 inch diameter electrode. 1-5%O2
Aluminium 25 30 * *
Carbon Steel * * 28 30
Low-alloy Steel * * 28 30
Stainless Steel 24 * 26 *
Nickel 26 30 * *
Copper 30 36 * *
*Not recommended.
7.4.3. Travel Speed.
After selecting a current and voltage setting, select the

rate of travel. A typical example is 0.6m – 0.76m per minute
(in./min). If the
rate is changed more than a few mm per minute, weld quality
will be greatly affected (Fig. 7.15).
J3103/7/21
No undercut. Undercutting.
Travel speed Travel speed
26 in/min 32 in/min
Fig. 7.15. Undercutting of horizontal fillet on 6.3mm thick

aluminium as affected by travel speed. Gas metal arc
process was used.
Position of welding will affect the travel speed. For

example, if the weld direction is dropped 15 degrees from flat so
that the position is slightly downhill, travel speed can be
increased.
7.4.4. Electrode Extension.
Electrode extension is important. The further the electrode

extends from the gun to the arc, the greater the electrical
resistance between the output terminals. Higher resistance
increases the temperature of the electrode, and the
resistance-heated electrode uses less current in the weld puddle.
In the spray-arc process, the electrode
extension should be about 12 mm to 25 mm, for short-circuiting
transfer; it should be approximately half this distance.
7.5. MIG WELDING TECHNIQUES

J3103/7/22
There are three methods of initiating the arc.

i. The gun switch operates the gas and water solenoids
and when released the wire drive is switched on
together with the welding current.
ii. The gun switch operates the gas and water solenoids
and strikes the wire end on the plate operates the
wire drives and welding current (known as ‘scratch
start’).
iii. The gun switch operates the gas and water solenoids
and wire feed with welding current known as ‘scratch
start’.
As a general rule dip transfer is used for thinner sections up to

6.4 mm and for positional welding, whilst spray transfer is used for
thicker sections.
The gun is held at an angle of 80 o or slight less to the line of the weld
to obtain a good view of the weld pool, and welding proceeds from
right to left with nozzle held 6 – 12 mm from the work.
The further the nozzle is held from the work less the efficiency of
the gas shield, leading to porosity. If the nozzle is held too close to the
work spatter may build up, necessitating frequent cleaning of the
nozzle, while acting between nozzle and work can be caused by a bent
wire guide tube allowing the wire to touch the nozzle, or by spatter
build-up short-circuiting wire and nozzle. If the wire burns back to the
guide tube it may be caused by a late start of the wire feed, fouling of
the wire in the feed conduit or the feed rolls being too tight.
Intermittent wire feed is generally due to insufficient feed rolls pressure
J3103/7/23
or looseness wire due to wear in the rolls. Excessively sharp bends in

the flexible guide tubes can also lead to this trouble.
Root run is performed with no weave and filler runs with as little
weave as possible consistent with good fusion since excessive weaving
tends to promote porosity. The amount of wire projecting beyond the
contact tube is important because the greater the projection, the
greater the I2R effect and the greater the voltage drop which may
reduce the welding current and affect penetration. The least projection
commensurate with accessibility to the joint being welded should be
aimed at.
Backing the strips which are welded permanently on to the
reverse side of the plate by the root run are often used to ensure
sound root fusion. Backing bars of copper or ceramics with grooves of
the required penetration bead profile can be used and are removed
after welding. It is not necessary to back-chip the root run of the light
alloys but with stainless steel this is often done and a sealing run put
down. The importance of fit-up in securing continuity and evenness of
the penetration bead cannot be over-emphasized.
Flat welds may be slightly tilted to allow the molten metal to flow
against the deposited metal and thus give a better profile. If the first
run has a very convex profile poor manipulation of the gun may cause
cold laps in the subsequent run.
7.6. DIRECT CURRENT STRAIGHT POLARITY
The welding circuit shown in figure 7.16, is known as a straight

polarity circuit. It is understood that the electrons are flowing from the
negative terminal (cathode) of the machine to the electrode. The
electrons continue to travel across the arc into the base metal and to
the positive terminal (anode) of the machine.
Approximately two-thirds of the total heat produced with DCSP is
released at the base metal while one-third is released at the electrode.
Reacto Arc
The choice of direct current straightr polarity dependsgap
on many
Electrod
variables such as material of the base metal, position
e
of the weld, as
well as the electrode material and covering. Work
piece
Cathod
ed
Holder
Fiel
d
Anod
J3103/7/24
Figure 7.16. Wiring diagram of a direct current, straight

7.7. polarity
DIRECT (DCSP)
CURRENT
arcREVERSE
circuit POLARITY ARC WELDING
It is possible, and sometimes desirable, to reverse the direction

of electron flow in the arc welding circuit. When electron flow from the
negative terminal (cathode) of the arc welder to the base metal, this
circuit is known as direct current reverse polarity (DCRP). In this case,
the electron returns to the positive terminal (anode) of the machine
from the electrode side of the arc, as shown in Figure 7.17.
Reacto Arc
r gap
Electrod
e
Work
piece
Anod
e Holder
Fiel
d
Cathod
ed
Figure 7.17. Wiring diagram of a direct current, reverse

polarity (DCRP) arc circuit
When using DCRP, one-third of the heat generated in the arc is

released at the base-metal and two-thirds is liberated at the electrode.
With two-thirds of the heat released at the electrode in DCRP, the
electrode metal and the shielding gas are super-heated. This
superheating causes the molten metal in the electrode to travel across
the arc at a very high rate of speed. Deep penetration results due to
J3103/7/25
the force of the high velocity arc. There is theory that, with a covered
electrode, a jet action and/or expansion of gases in the metal at the
electrode tip causes the molten metal to be propelled with great
impact across the arc.
The choice of direct current reverse polarity depends on many
variables such as material of the base metal, position of the weld, as
well as the electrode material and covering.
ACTIVITY 7
7.1. Explain the term nonconsumable electrode.
7.2. What does the term inert signify?
7.3. List the gases used for shielding a welding arc.
7.4. Explain how TIG welding electrodes are shaped.
7.5. How far should the electrode extend beyond the nozzle of the
TIG torch?
7.6. Explain why MIG welding is classified as a semiautomatic

process.
J3103/7/26
FEEDBACK ON ACTIVITY 7
7.1. The electrode does not melt into the weld.
7.2. The gas does not combine with the base metal or filler.
7.3. Argon, helium and carbon dioxide.
7.4. The electrode diameter should match the current value. If the
current is too high for the diameter of the electrode the life of the
electrode will be short. When the current is too low for a given
electrode diameter, the arc will not be stable. The end of the
electrode should remain bright, as if it was polished.
7.5. The electrode should extend beyond the nozzle a distance equal
to the electrode diameter.
7.5. MIG welding is classified as semi-automatic because the

electrode feeds into the weld according to a preset adjustment.
After making an initial adjustment, the welding operator merely
moves the gun along the joint. For effective applications, the
J3103/7/27
welding operator needs information concerning power

requirements, welding gun, selection of shielding gas, type of
filler metal, and job procedures.
SELF-ASSESSMENT 7
1. From the standpoint of operation, how are TIG and MIG processes
different? How are they similar?
2. What polarity does anode signify?
3. In what direction do the electrons travel when using straight

polarity?
4. How much of the heat used for arc welding is liberated at the
electrode when using straight polarity?
5. Why is it recommended that a tungsten electrode arc be started

on a scrap tungsten surface?
6. What would happen if the tungsten electrode were bent off

centre?
7. Name two defects that could occur with gas shielded-arc welding
processes and explain how each could be avoided.
J3103/7/28
FEEDBACK OF SELF-ASSESSMENT 7
1. TIG uses a tungsten electrode that does not melt into the weld;
because the electrode is shielded and cooled by inert gas flow. A
separate filler rod is used as needed
MIG uses a continuous electrode which feeds into the weld

automatically as an arc is maintained. . They both use inert gas.
Electrode
(tungsten)
Inert/noble
gas
Filler rode
Shielded gas
arc
Direction of travel
80 – 90o
20 – 30o
Melting pool
Work piece
TIG in progress. The tungsten does not melt into the

puddle for filler. This is a nonconsumable electrode.
J3103/7/29
Inert/noble gas
Shielded gas
Arc
Melting pool
Work piece
MIG in progress
2. Positive (+)
3. Across the arc into the base metal and to the positive terminal.
4. One-third (1/3)
5. To keep the tungsten electrode clean.
6. Uses more current and electrode will be jagged or contaminated.
7. (a) Eyes and skin – arc is more intense. Wear leather and
specially treated cloth.
(b) Breathing – provide adequate ventilation.

Unit 7 Shielded Gas Arc Welding: Objectives

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Unit 7 Shielded Gas Arc Welding: Objectives

Caricato da

Copyright:

Formati disponibili

J3103/7/1

SHIELDED GAS ARC WELDING

UNIT 7 SHIELDED GAS ARC WELDING

General Objective: To understand the principles of shielded

Specific Objectives : At the end of the unit you will be able

 Identify the principles of shielded gas arc

 Elaborate on the TIG and MIG welding

 State the advantages and disadvantages of

 State the weaknesses of TIG and MIG

The objective of welding is to produce a welding joint that

7.1. TUNGSTEN INERT GAS (TIG)

The welding of aluminium and magnesium alloys by the oxy-

metal to be welded. For metals having refractory surface oxides such

Figure 7.1. TIG welding

Figure 7.2. TIG in progress. The tungsten does not

Gas tungsten-arc processes must start with clean metal

aluminium since it aids in shielding. The backup bar may be

7.1.2. Joint Fit.

Good joints make it easier to obtain a good weld. In

7.1.3. Welding Machine.

Gas tungsten-arc welding requires a conventional welding

The finished weld will be greatly affected by type of current

(DCSP). Improper electrical connections will cause (a) the

Figure 7.3 Power supply with direct current

This causes nearly 70% of the arc heat to accumulate in

Figure 7.4 Power supply with direct current

In welding aluminium this method is used to remove

enough to melt, transfer to the weld pool, and contaminate the

Figure 7.5 Alternating current power

7.1.4. Welding Torch.

The welding torch has a round collet which compresses to

Electrode Nozzle or WELDING CURRENT IN AMPERES

1/16 4-6 50-100 70-150 70-150 10-20

The end of the electrode should remain bright, as if it was

Figure 7.6 Electrode shapes for gas shielded tungsten-arc

Figure 7.7. Adjustment of electrode

7.1.5. Shielding Gas.

Gas used with this process produces an atmosphere free

7.1.6. Filler Metal.

Filler metals are selected to meet or exceed the tensile

Metal Shielding Gas Remarks

7.2. TIG WELDING TECHNIQUES

Table 7.3 Operating data for TIG

Material Aluminium Stainless Magnesium Deoxidized

The shielded gas is pure argon and pre-heating is required for

position on the plate until a molten pool is obtained and welding is

Figure 7.8. Example of TIG

7.3. METAL INERT GAS (MIG)

It is convenient to consider, under this heading, those

equipment is essentially similar except for gas supply. With the

Spool of Inert gas

Contactor Control head

Figure 7.9 . MIG welding

Figure 7.10. MIG in

Figure 7.11. Mechanics of the short circuiting transfer

per unit of time.) Most applications of the spray-arc process are in

Electrode maintains steady arc length

Figure 7.12. Mechanics of the spray-arc

All metal inert-gas (MIG) welding is classified as semi-automatic,

7.3.1. Power Requirements.

Conventional power supplies used for shielded metal-arc

produces a constant voltage and also permits the operator to

selecting a wire feed rate. Slope adjustment to limit current is