WELDWELL NEW ZEALAND Private Bag 6025 NAPIER Telephone (06) 834-1600 Fax (06) 835-4568

INTRODUCTION
Our business is welding and we offer this handbook to both the handyman and industry in general, in an earnest endeavour to assist all those engaged in TIG welding. We have not covered all phases of welding, but present briefly, the basic facts of the TIG welding process and techniques.
LIST OF CONTENTS
History of TIG TIG Overview Power Sources Types of Welding Current used for TIG Characteristics of Current Types for Gas Tungsten Arc Welding TIG Handpiece (TIG Torch) Selecting the Correct Torch Nozzle Gas Lens Benefits Regulators Connection Diagrams Tungsten Selection and Preparation Tungsten Colour Code and Proper Torch Use TIG Wires Shielding Gas Shield Gas Selection and Use Typical Manual GTA (TIG Welding Parameters) Guide for Shield Gas Flows, Current Settings and Cup Selection Correct Torch and Rod Positioning Pulsed TIG Personal Protection Recognising Your Tungsten Operator Inspection for Weld Quality TIG Troubleshooting Guide

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Branches and Outlets throughout New Zealand Check your Yellow pages or www.weldwell.co.nz
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HISTORY OF GTAW (TIG WELDING)

TIG welding was, like MIG/MAG developed during 1940 at the start of the Second World War. TIGs development came about to help in the welding of difficult types of material, eg aluminium and magnesium. The use of TIG today has spread to a variety of metals like stainless mild and high tensile steels. GTAW is most commonly called TIG (Tungsten Inert Gas). The development of TIG welding has added a lot in the ability to make products, that before the 1940s were only thought of. Like other forms of welding, TIG power sources have, over the years, gone from basic transformer types to the highly electronic power source of the world today.

OVERVIEW
TIG welding is a welding process that uses a power source, a shielding gas and a TIG handpiece. The power is fed out of the power source, down the TIG handpiece and is delivered to a tungsten electrode which is fitted into the handpiece. An electric arc is then created between the tungsten electrode and the workpiece. The tungsten and the welding zone is protected from the surrounding air by a gas shield (inert gas). The electric arc can produce temperatures of up to 19,400oC and this heat can be very focused local heat. The weldpool can be used to join the base metal with or without filler material. The TIG process has the advantages of 1) Narrow concentrated arc 2) Able to weld ferrous and non-ferrous metals 3) Does not use flux or leave a slag 4) Uses a shielding gas to protect the weldpool and tungsten 5) A TIG weld should have no spatter 6) TIG produces no fumes but can produce ozone The TIG process is a highly controllable process that leaves a clean weld which usually needs little or no finishing. TIG welding can be used for both manual and automatic operations. The TIG welding process is so good that it is wisely used in the so-called high-tech industry applications such as 1) Nuclear industry 2) Aircraft 3) Food industry 4) Maintenance and repair work 5) Some manufacturing areas

POWER SOURCES
TIG welding power sources have come a long way from the basic transformer types of power sources which were used with add-on units to enable the power source to be used as a TIG unit, eg high frequency unit and/or DC rectifying units, The basics of TIG welding has almost remained the same, but the advent of technology TIG welding power sources have made the TIG processes more controllable and more portable in some cases. The TIG power source uses main power connected to a suitable power for the TIG process being used. This can be either AC or DC. The one thing that all TIGs have in common is that they are CC (Constant Current) type power sources. This means only output adjustment will control the power source amps. The voltage will be up or down depending on the resistance of the welding arc. A TIG power source can be of the AC or DC type. The principle of electric circuits will apply to only DC power sources. This means 70% of the heat is always on the positive side. So when a DC power source is used whatever is connected to the positive side will have 70% of the energy output (heat). When using an AC power source, which has an output of a wave form, the average on both terminals will be the same. This is because for one half of the wave form (cycle) the positive terminal will have 70% of the energy, but as the wave form moves to the other half of the cycle it will move to the negative terminal, which will then have the 70% of the energy. Other things to check on TIG power sources are 1) Amperage to do the job. Will it be sufficient? 2) Does the amperage go low enough for light material and high enough for thick material? 3) Power Supply - 400 Volt, 230 Volt - single or three phase. Is there enough main power to do the job? 4) Is weight a problem? If so, is the inverter type power source more suitable. 5) Will an engine driven power source be better to do the job? (Must have CC range). Might need suitable extra add-ons to do the eg, HF unit. 6) Would a multi-process type power source be better to do the job? Must have CC range. 7) Does the TIG welding need an AC power source or DC power source, as different material will need a different power type.

TYPES OF WELDING CURRENT USED FOR TIG

1)  DCSP - Direct Current Straight Polarity - (the tungsten electrode is connected to the negative terminal). This type of connection is the most widely used in the DC type welding current connections. With the tungsten being connected to the negative terminal it will only receive 30% of the welding energy (heat). This means the tungsten will run a lot cooler than DCRP. The resulting weld will have good penetration and a narrow profile. 2)  DCRP - Direct Current Reverse Polarity - (the tungsten electrode is connected to the positive terminal). This type of connection is used very rarely because most heat is on the tungsten, thus the tungsten can easily overheat and burn away. DCRP produces a shallow, wide profile and is mainly used on very light material at low amps. 3)  AC - Alternating Current is the preferred welding current for most white metals, eg aluminium and magnesium. The heat input to the tungsten is averaged out as the AC wave passes from one side of the wave to the other.  On the half cycle, where the tungsten is positive electron welding current will flow from base material to the tungsten. This will result in the lifting of any oxide skin on the base material. This side of the wave form is called the cleaning half. As the wave moves to the point where the tungsten becomes negative the electrons (welding current) will flow from the welding tungsten to the base material. This side of the cycle is called the penetration half of the AC wave form.   Because the AC cycle passes through a zero point the arc goes out. This can be seen with fast film photography. At this point the arc would stay out if it wasnt for the introduction of HF (high frequency). High frequency has very little to do with the welding process; its job is the re-ignition of the welding current as it passes through zero. (How good the HF is will often have a bearing on how well the re-ignition of the arc is.) HF is also often used for starting the welding arc initially without the tungsten touching the workpiece. This helps on materials that are sensitive to impurities. HF start can also be used on DC welding current to initially start the welding current without the tungsten touching the workpiece. t is a common misunderstanding that the HF does the cleaning action. I This is not the case, it only serves to re-ignite the welding arc.

4) AC - Alternating Current - Square Wave With the advent of modern electricity AC welding machines can now be produced with a wave form called Square Wave. The square wave has the benefit of a lot more control and each side of the wave can be, in some cases, controlled to give a more cleaning half of the welding cycle, or more penetration.

Once the welding current gets above a certain amperage (often depends on the machine) the HF can be turned off, allowing the welding to be carried on with the HF interfering with anything in the surrounding area.

CHARACTERISTICS OF CURRENT TYPES FOR GAS TUNGSTEN ARC WELDING

When TIG welding, there are three choices of welding current. They are: Direct Current Straight Polarity, Direct Current Reverse Polarity, and Alternating Current with High Frequency stabilisation. Each of these has its applications, advantages, and disadvantages. A look at each type and its uses will help the operator select the best current type for the job. The type of current used will have a great effect on the penetration pattern as well as the bead configuration. The diagrams below, show arc characteristics of each current polarity type.

CURRENT TYPE Electrode Polarity Oxide Cleaning Action Heat Balance in the Arc Penetration Profile Electrode Capacity

DCSP Electrode Negative No 70% at work end 30% at electrode end Deep, narrow Excellent

DC TIG POWER SUPPLY

TIG welding with DCSP (direct current straight polarity) produces deep penetration because it concentrates the heat in the joint area. No cleaning action occurs with this polarity.

DC TIG POWER SUPPLY

CURRENT TYPE Electrode Polarity Oxide Cleaning Action Heat Balance in the Arc Penetration Profile Electrode Capacity

DCRP Electrode Positive Yes 30% at work end 70% at electrode end Shallow, wide Poor

TIG welding with DCRP (direct current reverse polarity) produces good cleaning action as the argon ions flowing towards the work strike with sufficient force to break up oxides on the surface.

AC TIG POWER SUPPLY

CURRENT TYPE Electrode Polarity Oxide Cleaning Action Heat Balance in the Arc Penetration Profile Electrode Capacity

ACHF Alternating Yes (once every half cycle) 50% at work end 50% at electrode end Medium Good

TIG HANDPIECE (TIG TORCH)

The function of the TIG handpiece is to 1) hold the electrode tungsten 2 deliver welding current to the tungsten via a welding power cable 3)  deliver shielding gas to the TIG torch nozzle. The nozzle then directs the shielding gas to cover the weldpool protecting it from contamination from the surrounding air. 4)  often will be the way of getting the welder control circuit to the operation, eg on/off and/or amperage control. 5)  the TIG handpiece can be watercooled. Hoses in the TIG lead will supply cooling water to the TIG torch head assembly. 6)  the TIG torch length will allow a distance from the TIG power source and workpiece. TIG torches come in different styles depending on the brand being selected. But they all have things in common 1) aircooled or watercooled 2)  current rating. The operator must select the correct amperage rating TIG torch. Using a TIG torch that is not sufficiently rated for the machine may result in the TIG torch overheating. A TIG torch wiith an excessive rating may be larger and heavier than a lower amperage TIG torch. The TIG torch is made up of 1)  Leads - The lead will be set up for either aircooled or watercooled. It will be at a length suitable to do the job, eg 4 metre, 8 metre, etc. The lead will be made up of a power cable, gas hose and water leads in and out if the TIG torch is watercooled. The lead may also include a control lead. 2)  Tungsten Holders - Holders may vary with different brands of TIG torches. 3)  Nozzles - The nozzles job is to direct the correct gas flow over the weldpool. (Please see Selecting the Correct Torch Nozzle, page 10.) 4)  Back Caps - The back cap is the storage area for excess tungsten. They can come in different lengths depending on the space the torch may have to get into (eg. long, medium and short caps).

Please make sure when ordering a TIG torch to tell the supplier the amperage rating, whether water- or air-cooled, and the fitting that is to go on the end of the TIG torch lead suitable to fit the TIG power source it will be used from. This may include power cable fit up, gas fittings and control plug fittings.
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SELECTING THE CORRECT TORCH NOZZLE

Design diameter to fit GTAW torch

The exit diameter (diameter closest to the arc) is manufactured in a variety of sizes. GTAW nozzles are also made in various lengths from short nozzles to extra-long nozzles. Alumina nozzles, are the most commonly used nozzles in GTAW. Alumina nozzles are moulded from alumina oxide and the density of the alumina oxide determines the quality of the nozzle in relationship to impact resistance and thermal sock. Alumina nozzles are more impact resistant than lava nozzles. The impact resistance of the alumina nozzles makes them more durable and are used for general applications. The exit diameter for any nozzle is specified with a number that represents the diameter in 1.6 mm increments. A number 5 nozzle is therefore 8 mm diameter. A number 6 nozzle is 9.6 mm and so on. The diameter for any nozzle must be large enough to allow the entire weld area to be covered by the shielding gas. The exist diameter can be neither too large nor too small, or poor shield gas coverage will result. (Refer to page ? for correct cup size.)

Exit diameter measured in 1.6 mm

GAS LENS BENEFITS

A collet body with a gas lens can be very useful to a welder. The purpose of a gas lens is to make the shielding gas exist the nozzle as a column instead of as a turbulent stream of gas that begins to spread out after exiting. The column of gas allows the electrode to stick out farther for visibility, allowing for better access to the weld area, and a reduction in gas flow (CFH/L/Min.)

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REGULATORS
The function of the gas regulator is to reduce bottle pressure gas down to a lower pressure and deliver it at a constant flow. This constant flow of gas flows down through the TIG torch lead to the TIG torch nozzle and around the weldpool. There are three main styles of regulator used for TIG One made up with a single flow tube assembly (Fig. 1). Another made up with a twin-flow tubes assembly (Fig. 3) (this set-up is excellent for when purging is necessary). The third style does not have a flow tube and the flow is set by turning a handwheel (Fig. 2). The amount of gas flow needed to do the job will depend on the welding job being done and the type of material being welded. But a common setting to start with is 5 L/min.

Fig. 1

Fig. 3

Fig. 2
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CONNECTION DIAGRAMS

2 piece Cable Assembly FOR GAS COOLED TORCHES

Power Source Shield gas supply

FOR WATER COOLED TORCHES

TIG Torch Power Source Water out Power cable adaptor required WATER IN ARGON IN Coolant Recirculator RegulatorFlowmeter

Shield gas supply

Note: 1 litre per minute flow rate. Water in through water line. Water out through power cable.

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TUNGSTEN SELECTION AND PREPARATION

Base Metal Type Thickness Range Desired Results Welding Electrode Type Shield Gas Current Pure (EW-P) All General Purpose AC/HF Zirconiated (EW-Zr) 2% Thoriated (EW-Th2) sections Control penetration Increase penetration or travel speed DCRP 2% Ceriated (EW-Ce2) 2% Thoriated (EW-Th2) 2% Ceriated (EW-Ce2) 2% Thoriated (EW-Th2) 2% Ceriated (EW-Ce2) Zirconiated (EW-Zr) 2% Ceriated (EW-Ce2) 2% Thoriated (EW-Th2) All General Purpose DCSP 2% Ceriated (EW-Ce2) 2% Lanthanated (EWG-La2) Only thin sections Control penetration Increase penetration or travel speed ACHF Zirconiated (EW-Zr) 2% Ceriated (EW-Ce2) 2% Lanthanated (EWG-La2) Argon Argon 75 Argon 25 Helium Argon Helium 75 Argon 25 Helium Helium 75 Argon 25 Helium 75 Argon 25 Helium Argon 75 Argon 25 Helium 75 Argon 25 Helium 75 Argon 25 Helium 75 Argon 25 Helium Argon 75 Argon 25 Helium Helium Tungsten Performance Characteristics Balls easily, low cost, tends to spit at higher currents, used for non-critical welds only. Balls well, takes higher current, with less spitting and with better arc starts and arc stability than pure tungsten. Higher current range and stability, better arc starts, with lower tendency to spit, medium erosion. Lowest erosion rate, widest current range, AC or DC, no spitting, best arc starts and stability. Best stability at medium currents, good arc starts, medium tendency to spit, medium erosion rate. Low erosion rate, wide current range, AC or DC, no spitting, consistent arc starts, good stability. Best stability at medium currents, good arc starts, medium tendency to spit, medium erosion rate. Low erosion rate, wide current range, AC or DC, no spitting, consistent arc starts, good stability. Use on lower currents only, spitting on starts, rapid erosion rates at higher currents. Low erosion rate, wide current range, AC or DC, no spitting, consistent arc starts, good stability. Best stability at medium currents, good arc starts, medium tendency to spit, medium erosion rate. Low erosion rate, wide current range, AC or DC, no spitting, consistent arc starts, good stability. Lowest erosion rate, wide current range on DC, no spitting, best DC arc starts and stability. Use on lower currents only, spitting on starts, rapid erosion rates at higher currents. Low erosion rate, wide current range, no spitting, consistent arc starts, good stability. Lowest erosion rate, highest current range, no spitting, best DC arc starts and stability. 13

Aluminium Alloys and Magnesium Only thin Alloys

Only thick sections

DCSP

Copper Alloys, Cu-Ni Alloys and Nickel Alloys

Only thin sections Only thick sections All

General Purpose

DCSP

Control penetration Increase penetration or travel speed

ACHF

DCSP

Mild Steels, Carbon Steels, Alloy Steels and Titanium Alloys

Only thick sections

DCSP

TUNGSTEN COLOUR CODE AND PROPER TORCH USE

COLOUR CODE AND ALLOYING ELEMENTS FOR VARIOUS TUNGSTEN ELECTRODE ALLOYS
AWS Classifications EWP EWCe-2 EWLa-1 EWTh-1 EWTh-2 EWZr-1 EWG Colour* Green Orange Black Yellow Red Brown Grey Alloying Element Cerium Lanthanum Thorium Thorium Zirconium Not Specified** Alloying Oxide CeO2 La2O3 ThO2 ThO2 ZrO2 Nominal Weight of Alloying Oxide Percent 2 1 1 2 .25 -

* Colour may be applied in the form of bands, dots, etc, at any point on the surface of the electrode. ** Manufacturers must identify the type and nominal content of the rare earth oxide additions.

TUNGSTEN TIP PREPARATION

DCSP (EN) or DCRP (EP) Flat: 1/4 to 1/2 x dia 2-3 dia Taper Length ACHF General Purpose Max. ball 1 x dia Ball tip by arcing on clean metal at low current DCRP (EP) then slowly increase current to form the desired ball diameter. Return setting to AC.

TUNGSTEN EXTENSION
Standard Parts General Purpose 3 x dia.

TUNGSTEN GRINDING
Shape by grinding longitudinally (never radially). Remove the sharp point to leave a truncated point with a flat spot. Diameter of flat spot determines amperage capacity. (See below.) The included angle determines weld bead shape and size. Generally, as the included angle increases, penetration increases and bead width decreases. Use a medium (60 grit or finer) aluminium oxide wheel. 14

TIG WIRES
The selection of the TIG wire to be used in the TIG process is a decision that will depend on 1) The composition of the material being welded 2)  Mechanical properties of the weld material and those that are a match for the base material 3) Corrosion resistance should match 4) Joint design 5) Thickness of the base material 6) Cost

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SHIELDING GAS
Like other welding processes the job of the shielding gas is to protect the weld pool from contamination from air, which can cause porosity and defects in the weld. The shielding gas is a pathway for the welding arc and will help in the starting and running of the welding arc. In New Zealand the most common gas being used for TIG welding is Argon gas. Overseas Helium is also being used and in days gone by in some countries the weld process was called Heliarc welding. Each of these two gases has advantages. Argon

1) 2) 3) 4)

Better arc starting Good cleaning action Lower arc voltage Low gas flows needed

Helium 1) 2) 3)

Faster travel Better penetration Higher arc voltages

Because of the cost of Helium we are now seeing mixtures of Argon and Helium. This is to gain the best part of each gas. Please see your local gas

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SHIELD GAS SELECTION AND USE

Base Metal Type Thickness Range
Thin Thick General Purpose Thin Thick

Weld Type
Manual Manual Manual Mechanised Mechanised

Shield Gas Type

Pure Argon 75 Ar - 25 He Pure Argon 50 Ar - 50 He Pure Helium

Characteristics
Best arc starts, control of penetration, cleaning and appearance on thin gauges. Increase heat input with good arc starts of argon, but with faster welding speeds. Best overall for good arc starts, control of penetration, cleaning and appearance. Higher weld speed under 20mm thick, with good arc stability and starting. Highest weld speeds, deeper penetration with DCSP, demanding arc starting and fixturing requirements, high flow rates needed. Good control of weld puddle, bead contour, and penetration on thin gauges. Increase heat input with good arc starts of argon, but with faster welding speeds. Increase heat input with good arc starts of argon, but with faster welding speeds. Higher weld speed under 20mm thick, with good arc stability and starting. Highest weld speeds, deeper penetration with DCSP, demanding arc starting and fixturing requirements, high flow rates needed. Best arc starts, control of penetration, cleaning and appearance on thin gauges. Increase heat input with good arc starts of argon, but with faster welding speeds. Best overall for good arc starts, control of penetration, cleaning and appearance. Best overall for good arc starts, control of penetration, cleaning and appearance. Increase heat input with good arc starts of argon, but with faster welding speeds.

Aluminium Alloys and Magnesium Alloys

Thin

Manual Manual Manual Mechanised Mechanised

Pure Argon 75 Ar - 25 He 75 Ar - 25 He 25 Ar - 75 He Pure Helium

Copper Alloys Cu-Ni Alloys Nickel Alloys

Thick General Purpose Thin Thick

Thin Thick General Purpose Thin Thick

Manual Manual Manual Mechanised Mechanised

Pure Argon 75 Ar - 25 He Pure Argon Pure Argon 75 Ar 25 He

Low Carbon Alloys and Low Alloy Steels

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TYPICAL MANUAL GTA (TIG) WELDING PARAMETERS

ALUMINIUM (ACHF)
Metal Gauge 1.6 mm 3.2 mm 4.8 mm 6.4 mm Joint Type Butt Fillet Butt Fillet Butt Fillet Butt Fillet Tungsten size 1.6 mm 2.4 mm 3.2 mm 4.8 mm Filler Rod Size 1.6 mm 2.4 mm 3.2 mm 3.2 mm 3.2 mm Cup Size 4, 5, 6 6, 7 7, 8 8, 10 Shield Gas Flow Type Argon Argon Argon/ Helium Argon/ Helium CFH (L/Min) 15 (7) 17 (8) 21 (10) 25 (12) PSI 20 20 20 20 Welding Amperes 60-80 70-90 125-145 140-160 190-220 210-240 260-300 280-320 Travel Speed 307 mm 256 mm 307 mm 256 mm 258 mm 230 mm 256 mm 205 mm

WELDING ALUMINIUM The use of TIG welding for aluminium has many advantages for both manual and automatic processes. Filler metal can be either wire or rod and should be compatible with the base alloy. Filler metal must be dry, free of oxides, grease, or other foreign matter. If filler metal becomes damp, heat for 2 hours at 120oC before using. Although ACHF is recommended, DCRP has been successful up to 2.4mm, DCSP with helium shield gas is successful in mechanised applications. MAGNESIUM (ACHF)
Metal Gauge 1.6 mm 3.2 mm 6.4 mm 12.8 mm Joint Type Butt Fillet Butt Fillet Butt Butt(2) Butt(2) Tungsten size 1.6 mm 2.4 mm 4.8mm 6.4 mm Filler Rod Size 2.4 mm 3.2 mm 3.2 mm 4.0 mm 4.0 mm 4.8 mm Cup Size 5, 6 7, 8 8 10 Shield Gas Flow Type Argon Argon Argon Argon CFH (L/Min) 13 (5) 19 (9) 25 (12) 35 (17) PSI 15 15 15 15 Welding Amperes 60 60 115 115 100-130 110-135 260 Travel Speed 512 mm 435 mm 563 mm 512 mm 256 mm

WELDING MAGNESIUM Magnesium alloys are in three groups, they are (1) aluminium-zinc-magnesium, (2) aluminiummagnesium, and (3) maganese-magnesium. Since magnesium absorbs a number of harmful ingredients and oxidize rapidly when subjected to welding heat, TIG welding in an inert gas atmosphere is distinctly advantageous, the welding of magnesium is similar, in many respects, to the welding of aluminium. Magnesium was one of the first metals to be welded commercially by TIG. Magnesium requires a positive pressure of argon as a backup on the root side of the weld.
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STAINLESS STEEL (DCSP)

Metal Gauge 1.6 mm 3.2 mm 4.8 mm 6.4 mm Joint Type Butt Fillet Butt Fillet Butt Fillet Butt Fillet Tungsten size 1.6 mm 1.6 mm 2.4 mm 2.4 mm 3.2 mm 3.2 mm Filler Rod Size 1.6 mm 2.4 mm 3.2 mm 4.8 mm Cup Size 4, 5, 6 4, 5, 6 5, 6, 7 8, 10 Shield Gas Flow Type Argon Argon Argon Argon CFH (L/Min) 11 (5.5) 11 (5.5) 13 (6) 13 (6) PSI 20 20 20 20 Welding Amperes 80-100 90-100 120-140 130-150 200-250 225-275 275-350 300-375 Travel Speed 307mm 256 mm 307 mm 256 mm 307 mm 256 mm 256 mm 205 mm

WELDING STAINLESS STEEL In TIG welding of stainless steel, welding rods having the AWS-ASTM prefixes of E or ER can be used as filler rods. However, only bare uncoated rods should be used. Stainless steel can be welded using ACHF, however, recommendations for DCSP must be increased 25%. Light gauge metals less than 1.6 mm thick should always be welded with DCSP using argon gas. Follow the normal precautions for welding stainless such as: Clean surfaces; dry electrodes; use only stainless steel tools and brushes, carefully remove soap from welds after pressure testing; keep stainless from coming in contact with other metals. LOW ALLOY STEEL (DCSP)
Metal Gauge 1.6 mm 3.2 mm 4.8 mm 6.4 mm Joint Type Butt Fillet Butt Fillet Butt Fillet Butt Fillet(2) Tungsten size 1.6 mm 1.6 mm 2.4 mm 2.4 mm 3.2 mm Filler Rod Size 1.6 mm 2.4 mm 3.2 mm 4.0 mm Cup Size 4, 5, 6 4, 5, 6 7, 8 8, 10 Shield Gas Flow Type Argon Argon Argon Argon CFH (L/Min) 15 (7) 15 (7) 16 (6.5) 18 (8.5) PSI 20 20 20 20 Welding Amperes 95-135 95-135 145-205 145-205 210-260 210-260 240-300 240-300 Travel Speed 384 mm 384 mm 282 mm 282 mm 256 mm 256 mm 256 mm 256 mm

WELDING LOW ALLOY STEEL Mild and low carbon steels with less than 0.30% carbon and less than 25 mm thick, generally do not require preheat. An exception to this allowance is welding on highly restrained joints. These joints should be preheated 10 to 38oC to minimise shrinkage cracks in the base metal. Low alloy steels such as the chromium-molybdenum steels will have hard heat affected zones after welding, if the preheat temperature is too low. This is caused by rapid cooling of the base material and the formation of martensitic grain structures. A 90 to 200oC preheat temperature will slow the cooling rate and prevent the martensitic structure.
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GUIDE FOR SHIELD GAS FLOWS, CURRENT SETTINGS AND CUP SELECTION
Welding Current (Amps) - Tungsten Type
AC Zirconiated
5 - 20 15 - 80 70 - 150 140 - 235 220 - 325 300 - 425 400 - 525 500 - 700

Electrode Diameter (mm)

0.50 1.00 1.60 2.40 3.20 4.00 4.80 6.40

Argon Flow - Ferrous Metals

Standard Body
5-8 (3-4) 5-10 (3-5) 7-12 (4-6) 10-15 (5-7) 10-18 (5-9) 15-27 (7-12) 20-35(10-17) 25-50(12-24)

Argon Flow - Aluminium

Standard Body
5-8 (3-4) 5-12 (3-6) 8-15 (4-7) 10-20 (5-10) 12-25 (6-12) 15-30 (7-14) 25-40 (12-19) 30-55 (14-26)

Cup Size

DCSP Thoriated
5 - 20 20 - 80 50 - 150 135 - 235 240 - 350 350 - 500 475 - 800 700 - 1100

CFH (L/min)

CFH (L/min)

Gas Lens Body

5-8 (3-4) 5-8 (3-4) 5-10 (3-5) 8-10 (4-5) 8-12 (4-6)

CFH (L/min)

CFH (L/min)

Gas Lens Body

5-8 (3-4) 5-10 (3-5) 7-12 (4-6)

3, 4 or 5 4 or 5 4, 5 or 6 6, 7 or 8 7, 8 or 10 8 or 10 8 or 10 10

10-15 (5-7) 10-20 (5-10) 12-25 (6-12) 15-30 (7-14) 25-45 (12-21)

10-15 (5-7) 12-25 (6-12) 20-35 (10-17)

CORRECT TORCH AND ROD POSITIONING

Vertical

Tungsten Electrode Welding Rod 60o - 75o Shield Gas 15o - 30o Direction of Travel Nozzle

The suggested electrode and welding rod angles for welding a bead on plate. The same angles are used when making a butt weld. The torch is held 60o - 75o from the metal surface. This is the same as holding the torch o o 15 - 30 from the vertical. Take special note that the rod is in the shielding gas during the welding process.
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PULSED TIG
Pulsed TIG has the advantages of 1) better penetration with less heat 2) less distortion 3) better control when welding out of position 4) Easy to use on thin materials The down side is - more set-up cost and more operator training. Pulsed TIG consists of Peak Current - This is set up higher than for non-pulsed TIG. Background Current - This is set lower than peak current and is the bottom current the pulse will drop to, but must be enough to keep the arc alive. Pulses Per Second - This is the number of times per second that weld current reaches peak current. % on Time - This is the pulse peak duration as a percentage of the total time, which controls how long the peak current is on for before dropping to the background current.

Down Slope - This is the way and the time taken for the welding current to wind down at the end of the TIG weld. Down slope will help prevent the uneven cooling of the final weld pool and will help stop pinholes forming at the completion of a TIG weld. Post Flow - Post flow is the time taken for the shielding gas to stay on after the welding current has stopped. This time will 1) protect the end of the weld 2)  protect the cooling down of the tungsten (the oxidation of the tungsten). Pre-Flow - Preflow is used at the start of the welding process to help protect the start of the weld from contamination and to make sure the shielding gas is flowing before the welding current starts up.

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PERSONAL PROTECTION
Skull Cap Helmet Mask

Jacket

Welding helmet lens

Gloves

TIG WELDING HAZARDS 1) Gases - Ozone is formed under the extreme temperature of the arc. 2) Heat 3)  Ultra Violet Light - TIG produces one of the highest ratio of ultra violet light per amperage of any welding process. 4)  Fumes - coming from the heating of the base material and the burning of any contaminates that might be present. 5) Magnetic fields may interfere with medical devices. 6)  HF Radiation - can cause interference with other equipment, eg computers and communication equipment.

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RECOGNISING YOUR TUNGSTEN

A B C D E F G

Electrode A has the ball end. This pure tungsten was used with alternating current on aluminium. Notice the end is uniform in shape and possesses a shiny bright appearance. Electrode B is a 2% thoriated tungsten ground to a taper and was used with direct current straight polarity. Electrode C is a 2% thoriated tungsten which was used with alternating current on aluminium. Note that this electrode has several small ball shaped projections rather than a round complete ball end like the pure tungsten. Electrode D is a pure tungsten used with alternating current on aluminium. This electrode was subjected to a current above the rated capacity. Notice the ball started to droop to one side. It becomes very molten during operation and continuing to operate would have caused the molten end to drop into the weld puddle. Electrode E is a pure tungsten that was tapered to a point and used on direct current straight polarity. Notice the ball tip characteristic of the pure tungsten. Pointing of pure tungsten is not recommended as the extreme point will always melt when the arc is established. The electrode in this illustration melted back, however, often times the point may melt and drop into the weld puddle. Electrode F was severely contaminated by touching the filler rod to the tungsten. In this case the contaminated area must be broken off and the electrode reshaped as desired. Electrode G did not have sufficient gas post-flow. Notice the black surface which is oxidized because the atmosphere contacted the electrode before it cooled sufficiently. If this electrode were used the oxidized surface will flake off and drop into the weld puddle. Post-flow time should be increased so the appearance is like electrode A after welding.
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OPERATOR INSPECTION FOR WELD QUALITY

PROBLEM: CAUSE:

Excessive build up Poor penetration Poor fusion at edges

Welding current too low

PROBLEM:

Bead too wide and flat Welding current too high Poor penetration Excessive burn through

CAUSE:

PROBLEM:

Bead too small Travel speed too fast Insufficient penetration Ripples widely spaced

CAUSE:

PROBLEM:

Bead too wide Travel speed too slow Excessive build up Excessive penetration

CAUSE:

PROBLEM:

Undercut Welding current too high Insufficient weld deposit and/or wrong placement of Uneven penetration filler rod

CAUSE:

PROBLEM:
Poor penetration Poor fusion

CAUSE:

Faulty joint preparation and too low welding current

PROBLEM:

Proper build-up Good appearance good penetration Bead edges fused in

CAUSE:

Correct technique and current setting

PROBLEM:

No undercut Correct technique and  Legs of fillet weld equal current setting to metal thickness Slightly convex bead face

CAUSE:

24

TIG TROUBLESHOOTING GUIDE

Problem Cause 1. Inadequate gas flow 2. Improper size electrode for current required 3. Operating of reverse polarity 4. Electrode contamination 5. Excessive heating inside torch 6. Electrode oxidising during cooling 7. Shield gas incorrect 1. Incorrect voltage (arc too long) 2. Current too low for electrode size 3. Electrode contaminated 4. Joint too narrow 5.  Contaminated shield gas, dark stains on the electrode or weld bead indicate contamination 6. Base metal is oxidised, dirty or oily 1. Poor scratch starting technique Solution 1. Increase gas flow 2. Use larger electrode 3. Use larger electrode or change polarity 4. Remove contaminated portion, then prepare again 5. Replace collet, try wedge collet or reverse collet 6. Increase gas post flow time to 1 sec. per 10 amps 7. Change to proper gas (no oxygen or CO2) 1. Maintain short arc length 2. Use smaller electrode or increase current 3. Remove contaminated portion, then prepare again 4. Open joint groove 5.  The most common cause is moisture or aspirated air in gas stream. Use welding grade gas only. Find the source of the contamination and eliminate it promptly 6.  Use appropriate chemical cleaners, wire brush, or abrasives prior to welding

Excessive Electrode Consumption

Erratic Arc

Inclusion of Tungsten or Oxides in Weld

1.  Many codes do not allow scratch starts. Use copper strike plate. Use high frequency arc starter 2. Excessive current for tungsten size used 2. Reduce the current or use larger electrode 3. Accidental contact of electrode with puddle 3. Maintain proper arc length 4. Accidental contact of electrode to filler rod 4.  Maintain a distance between electrode and filler 5. Using excessive electrode extension metal 5.  Reduce the electrode extension to recommended 6. Inadequate shielding or excessive draughts limits 6.  Increase gas flow, shield arc from wind, or use gas 7. Wrong gas lens 7.  Do not use ArO2 or ArCO2 GMA (MIG) gases for TIG 8. Heavy surface oxides not being removed welding 8.  Use ACHF, adjust balance control for maximum cleaning, or wire brush and clean the weld joint prior to welding. 1.  Entrapped impurities, hydrogen, air, nitrogen, water vapour 2. Defective gas hose or loose connection 3.  Filler material is damp (particularly aluminium) 4. Filler material is oily or dusty 5.  Alloy impurities in the base metal such as sulphur, phosphorous, lead and zinc 6.  Excessive travel speed with rapid freezing of weld trapping gases before they escape 7. Contaminated shield gas 1.  Do not weld on wet material. Remove condensation from line with adequate gas pre-flow time 2. Check hoses and connections for leaks 3. Dry filler metal in oven prior to welding 4. Replace filler metal 5.  Change to a different alloy composition which is weldable. These impurities can cause a tendency to crack when hot 6. Lower the travel speed 7. Replace the shielding gas

Porosity in Weld Deposit

Cracking in Welds

1.  Hot cracking in heavy section or with metals 1.  Preheat, increase weld bead cross-section size, which are hot shorts change weld bead contour. Use metal with fewer alloy impurities 2.  Crater cracks due to improperly breaking 2.  Reverse direction and weld back into previous weld the arc or terminating the weld at the joint at edge. Use Amptrak or foot control to manually edge down slope current 3.  Post weld cold cracking, due to excessive 3.  Preheat prior to welding, use pure or nonjoint restraint, rapid cooling, or hydrogen contaminated gas. Increase the bead size. Prevent embrittlement craters or notches. Change the weld joint design 4. Centreline cracks in single pass welds 4.  Increase bead size. Decrease root opening, use preheat, prevent craters 5.  Underbead cracking from brittle 5.  Eliminate sources of hydrogen, joint restraint, and microstructure use preheat

25

TIG TROUBLESHOOTING GUIDE (continued)

Problem Cause 1. Gas flow blockage or leak in hoses or torch 2.  Excessive travel speed exposes molten weld to atmospheric contamination 3. Wind or draughts 4. Excessive electrode stickout 5. Excessive turbulence in gas stream 1.  Induced magnetic field from DC weld current 2. Arc is unstable due to magnetic influences 1. Short water cooled leads life 2. Cup shattering or cracking in use Short Parts Life 3. Short collet life 4. Short torch head life 5.  Gas hoses ballooning, bursting, or blowing off while hot Solution 1. Locate and eliminate the blockage or leak 2.  Use slower travel speed or carefully increase the flow rate to a safe level below creating excessive turbulence. Use a trailing shield cup 3. Set up screens around the weld area 4. Reduce electrode stickout. Use a larger size cup 5. Change to gas saver parts or gas lens parts 1.  Change to ACHF current. Rearrange the split ground connection 2.  Reduce weld current and use arc length as short as possible 1.  Verify coolant flow direction, return flow must be on the power cable lead 2.  Change cup size or type, change tungsten position, refer to chart 3.  Ordinary style is split and twists or jams, change to wedge style 4.  Do not operate beyond rated capacity, use water cooled model, do not bend rigid torches 5. I ncorrect flowmeter, TIG flowmeters operate at 35 psi with low flows. MIG flowmeters operate with high flows at 65 psi or more.

Inadequate Shielding

Arc Blow

26