GTAW

(TIG)
 Definition

Gas Tungsten Arc Welding (GTAW) is an arc welding process that

uses a non consumable tungsten electrode to establish the arc and
gas from a cylinder to provide shielding. The filler metal is supplied
by a manual rod.

Also called Tungsten Inert Gas (TIG) welding.

2
 Machine Functions

1 Store and provide shielding gas at the correct

rate
2 Provide desired welding current
3 Variable current control
4 Store and circulate water through the torch
(watered cooled)
5 Semiautomatic control
 Machine Nomenclature

A. Torch
B. Power switch
C. AC balance control
D. Mode switch
E. Digital Amp meter
F. Output (Amp) control
G. Cylinder
H. Flow meter
I. Roto meter
J. Flow control valve
K. Regulator
L. Post flow timer
M. Pulse frequency control
N. Polarity switch
O. Output connector
P. Remote pedal
Q. Ground clamp
Explain the function(s) of each one of these
R. Remote receptacle
controls/parts.
 Torch Nomenclature

A. Cap
B. Collet
C. Torch body
D. Collet body
E. Gas orifice
F. Cup
G. Electrode

What is the function of each part?

How are GTAW torches cooled?

 Introduction

How does the GTAW process meet the three

requirements of arc welding?

Heat Shielding Filler metal

GTAW
 Hazards Associated with GTAW

Hot metal
Harmful rays
Fumes
High frequency RF
Flying objects
Loud Noise

What is the best management practices for these hazards?

 Heat

The heat produced by an electric arc between the

nonconsumable tungsten and the metal is sufficient to melt
the base metal and the filler rod.

What determines the amount of heat produced by the

electric arc?

For the TIG welding process, is the current adjusted by

changing the amperage or the voltage?
 Heat Currents

Three common currents:

DC-
DC+
AC--HF

Note: many power supplies have the option of pulsed

current for better puddle control.

Why is HF (high frequency) used with AC?

 Heat Current - Polarity

For the best welds, and

ease of welding, the
correct current must be
used for the metal being
welded.
 Heat - Tungsten
The tungsten electrode is nonconsumable and is used to form the arc
between the torch and the metal.
Different alloys of tungsten are available.

ID % Alloy Color Characteristic

EWP 100 % Tungsten Green Good arc stability with AC

EWTh-2 2 % Thorium Red Better Arc with DC

EWZr-1 1 % Zirconium Brown AC when high weld quality is required

EWCe-2 2 % Cerium Orange Better starting, higher current

EWLa-2 2 % Lanthanum Black 50% greater current capacity with AC

Which alloy/color should be used when welding thicker aluminum with AC?
 Heat Tungsten - Preparation

The shape of the tungsten electrode end must be

appropriate for the current being used.
AC Hemispheric or balled end no more than 1.5 times the electrode
diameter. Grinder lines parallel with electrode.
DC- Needle point for very thin metal, blunt point for thicker metal.
Taper = 2 to 2-1/2 times the diameter.

What does it mean if the end of the electrode appears dull?

What does it mean if the end of the electrode is blue or blackened?

How long should the the shielding gas flow after the welding has stopped?
 Heat Tungsten - Size

Diameter Gas Cup DC- AC AC

(in) Inside Dia. (Ce, Th % La) (Pure) (Ce, Th % La)
0.040 #5 (3/8 in) 15 80 20 60 15 - 80
0.060 (1/16 in) #5 (3/8 in) 70 - 150 50 100 70 150
0.093 (3/16 in) #8 (1/2 in) 150 250 100 - 160 140 235
0.125 (1/8 in) #8 (1/2 in) 250 400 150 200 225 - 325
 Shielding
In the GTAW process shielding is supplied from a cylinder.

How is the flow of the shielding gas controlled?

For best results the

shielding gas must be
appropriate for the type
and thickness of metal.

How much gas (ft3) will

each gallon of liquid
argon produce?
 Filler Metal

A welding rod is used to fill in the joint.

Most common type is 36 inch rods that are fed into the
weld pool by hand.

What are three important characteristics of GTAW rods?

AWS GTAW Aluminum Filler Rods

Aluminum
Alloy Filler Rod
1100 ER1100
2014-T6 ER4043
2219-T81 ER2319
3003 ER1100
5005 ER5356
Process
 Preparation for Welding

Three (3) steps in preparing to weld:

1 Safety check
2 Metal preparation
3 Set up machine
 Preparation - Safety

1 Check the machine, cables, torch and ground clamp.

2 Insure the helmet is in good condition and the correct
shade of lens.
3 Cover all exposed skin.
 Preparation Metal Aluminum

Contamination is the biggest problem when welding

aluminum with the GTAW process.
The metal must be cleaned with a stainless steel wire
brush.
The brush can only be used to clean aluminum.
Must clean the adjoining faces and the back edge
Insure the filler rod is clean also.
 Preparation - Machine

Attach the GTAW torch to the output connector.

Attach the remote control pedal to the remote
receptacle.
Position the polarity switch on AC.
Turn on the machine.
Insure the torch is not grounded
Set the mode switch to TIG
Set the amperage.
150 amp maximum for air cooled torch.
Set the AC balance control.
Set the pulse control.
Set the postflow timer.
 Preparation Machine - Torch

If the torch has been used to weld carbon steel or

stainless steel then the cup and electrode must
be replaced.
The tungsten electrode must be clean and the
correct shape.
The torch cup must be clean
The electrode must be set with the correct
stickout.
Welding aluminum
 Setting Amperage

Aluminum is a good conductor of heat.

Aluminum melts at a lower temperature that steel.
Aluminum Amperage ACHF
Tungsten Gas
electrode Filler rod
Type CFH
Thickness Joint diameter diameter Amperage
Butt 3/32 1/8 in 3/32 in 125 - 150 Argon 20
Lap 3/32 1/8 in 3/32 in 130 - 160 Argon 20
1/8 in
Corner 3/32 1/8 in 3/32 in 120 - 140 Argon 20
Fillet 3/32 1/8 in 3/32 in 130 - 160 Argon 20
Butt 1/8 5/32 in 1/8 in 180 - 225 Argon 20
3/16 in
Lap 1/8 5/32 in 1/8 in 190 - 240 Argon 20
Corner 1/8 5/32 in 1/8 in 180 - 225 Argon 20
Fillet 1/8 5/32 in 1/8 in 190 240 Argon 20
Butt 5/32 3/16 3/16 in 240 - 280 Argon 25
1/4 in in
Lap 5/32 3/16 3/16 in 250 320 Argon 25
in
Corner 5/32 3/16 3/16 in 240 - 280 Argon 25
in
 Troubleshooting GTAW

Troubleshooting is the process of determining the

cause of a problem.
Assumes the welder is in proper working order.
Requires gathering information and a logical
thought process.
 Troubleshooting - 1

Problem Cause

Excessive electrode consumption Inadequate gas flow

DCEP electrode

Excessive current density

Tungsten oxidation during cooling

What would you do to remedy these causes?

 Troubleshooting - 2

Problem Cause

Aluminum contamination of electrode Electrode contacting filler rod

Electrode contacting metal

What would you do to remedy these causes?

 Troubleshooting - 3

Problem Cause

Weld porosity and dark color Condensation in system

Atmospheric contamination

Contaminated filler metal

What should be done to remedy
these causes? Contaminated base metal
 Troubleshooting - 4

Problem Cause

Yellow powder or smoke on cup Insufficient gas flow

Atmospheric contamination

Inadequate post flow

What should be done to remedy
these causes? Incorrect shielding gas

Incorrect tungsten size or cup size

 References

http://www.millerwelds.com/resources/TIGhandbook/