Professional Documents
Culture Documents
2008−03
Processes
TIG (GTAW) Welding
Guidelines For
Gas Tungsten Arc
Welding (GTAW)
Protect yourself and others from injury — read and follow these precautions.
D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord for damage or bare wiring −
repair this unit. replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
During operation, keep everybody, especially children, away. D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill. D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Touching live electrical parts can cause fatal shocks D Do not touch electrode if you are in contact with the work, ground,
or severe burns. The electrode and work circuit is or another electrode from a different machine.
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also D Do not touch electrode holders connected to two welding ma-
live when power is on. In semiautomatic or automatic wire welding, the chines at the same time since double open-circuit voltage will be
wire, wire reel, drive roll housing, and all metal parts touching the present.
welding wire are electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Wear dry, hole-free insulating gloves and body protection.
D Keep all panels and covers securely in place.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work D Clamp work cable with good metal-to-metal contact to workpiece
or ground. or worktable as near the weld as practical.
D Do not use AC output in damp areas, if movement is confined, or if D Insulate work clamp when not connected to workpiece to prevent
there is a danger of falling. contact with any metal object.
D Use AC output ONLY if required for the welding process. D Do not connect more than one electrode or work cable to any
D If AC output is required, use remote output control if present on single weld output terminal.
unit.
D Additional safety precautions are required when any of the follow-
SIGNIFICANT DC VOLTAGE exists in inverter-type
ing electrically hazardous conditions are present: in damp welding power sources after removal of input
locations or while wearing wet clothing; on metal structures such power.
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can cause severe burns.
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone! D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or D Allow cooling period before working on gun or
servicing this equipment. Lockout/tagout input power according to torch.
OSHA 29 CFR 1910.147 (see Safety Standards). D To handle hot parts, use proper tools and/or
D Properly install and ground this equipment according to its wear heavy, insulated welding gloves and
Owner’s Manual and national, state, and local codes. clothing to prevent burns.
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
5. Connect work clamp to workpiece as close to the weld as possi-
frequency electric and magnetic fields is a human-health hazard.”
ble.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you About Implanted Medical Devices:
may wish to minimize your exposure to electromagnetic fields when Implanted Medical Device wearers should consult their doctor and the
welding or cutting. device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
To reduce magnetic fields in the workplace, use the following If cleared by your doctor, then following the above procedures is recom-
procedures: mended.
D Concentrated Arc - Permits pin point control of heat input to the workpiece resulting in a narrow heat-affected zone
D No Slag - No requirement for flux with this process; therefore no slag to obscure the welder’s vision of the molten
weld pool
D No Sparks or Spatter - No transfer of metal across the arc. No molten globules of spatter to contend with and no
sparks produced if material being welded is free of contaminants
D Little Smoke or Fumes - Compared to other arc-welding processes like stick or flux cored welding, few fumes are
produced. However, the base metals being welded may contain coatings or elements such as lead, zinc, copper,
nickel and so on, that may produce hazardous fumes. Keep your head and helmet out of the fumes rising off the
workpiece. Be sure that proper ventilation is supplied, especially in a confined space.
D Welds more metals and metal alloys than any other process
D Good for welding thin material
Disadvantages of GTAW welding:
5
Ref. 804 846-A
4
3
Whenever possible and practical, use DC weld output instead of AC weld output.
4-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten )
2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens
.010 in. (1 mm) Up to 25 Up to 20
.020 in. (1 mm) 15-40 15-35
.040 in. (1 mm) 25-85 20-80
1/16 in. (1.6 mm) 50-160 50-150
3/32 in. (2.4 mm) 135-235 130-250
1/8 in. (3.2 mm) 250-400 225-360
5/32 in. (4.0 mm) 400-500 300-450
3/16 in. (4.8 mm) 500-750 400-500
1/4 in. (6.4 mm) 750-1000 600-800
Pure Tungsten (Green Band)
.040 in. (1 mm) Pure Tungsten Not Recommended 10-60
1/16 in. (1.6 mm) For DCEN − Argon 50-100
3/32 in. (2.4 mm) 100-160
1/8 in. (3.2 mm) 150-210
♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use
local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor-
mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ-
mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
Preparing Tungsten For DC Electrode Negative (DCEN) Welding or AC Welding With Inverter Machines
1 Grinding Wheel
2-1/2 Times Grind end of tungsten on fine grit, hard
Radial Grinding Electrode Diameter abrasive wheel before welding. Do not use
Causes Wandering Arc 2 wheel for other jobs or tungsten can become
3
contaminated causing lower weld quality.
1 2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage
4
capacity.
Wrong Tungsten Preparation
Ideal Tungsten Preparation − Stable Arc 4 Straight Ground
Grind lengthwise, not radial.
1 Tungsten Electrode
1 − 1-1/2 Times A pure tungsten is recommended.
Electrode Diameter 2 Balled End
Ball end of tungsten by applying AC amper-
1 2 age recommended for a given electrode
diameter (see Section 4-1). Let ball on end of
the tungsten take its own shape.
1 AC Sine Wave
1
2 Weld Sample
Time
40.0
30.0
+
20.0
Current
0 10.0
Amperage
0.0
−10.0
−
−20.0
Time −30.0
1/60 Second
−40.0
1 Zero Crossover
. The percentage of time spent
in the Zero Crossover Area
affects the quality of the
welding arc.
+
Current
Current
0
1 Conventional Squarewave AC
2 Weld Sample
. Faster transition time between
1 electrode positive and elec-
trode negative.
Time
40.0
30.0
20.0
+
10.0
Amperage
Current
0
0.0
−10.0
−20.0
−
−30.0
−40.0
. Arc shaping capabilities are enhanced by improved balance control, AC frequency control and independent amperage control.
6-2. Balance Control
1 More EP Time
Shallower penetration.
2 More EN Time
Deeper penetration, faster travel
speeds.
1 2
1 Low AC Frequency
Soft, wide arc with shallower
penetration.
2 High AC Frequency
Focused arc with deeper
penetration.
1 2
1 More EP Amperage
Wide, shallow penetration.
2 More EN Amperage
Narrow, deep penetration, faster
travel speeds.
1 2
1 AC Waveform
2 Weld Sample
1
At 60 Hz the bead doesn’t quite
penetrate the thick aluminum.
+ . Lower AC frequencies create a
wider arc cone.
Current
1/60th of
a second
1 AC Waveform
2 Weld Sample
1
At 200 Hz the bead is much tighter
and penetrated the thicker metal.
+ . Higher AC frequencies create
a narrower arc cone.
Current
1/200th of
a second
Cleaning Good cleaning action Less cleaning action Cleaning properties closer to Argon
Flow Rate Lower flow rates 10-30 CFH Higher flow rates (2 times) Higher flow rates than Argon
Cost Lower cost and greater availability Higher cost than Argon Costs higher than Argon
75° 15°
Welding direction
Notes
20°
70°
20°
10°
ST-162 003 / S-0792
70°
20°
30°
ST-162 003 / S-0792
20°
2 To 3 in.
(51-76 mm)
2 To 3 in.
(51-76 mm)
2
1/4 in. 2
(6.4 mm) 1 1
S-0057-B
9-1. Troubleshooting
Inadequate gas flow. Check to be sure hose, gas valve, and torch are not restricted or the tank is not out of gas. Gas flow
should typically be set at 15 to 20 CFH.
Improper size tungsten for current Change tungsten - General purpose tungsten size is 3/32 in. diameter at a maximum of 235 amps.
used.
Excessive heating in torch body. Air-cooled torches get very warm. If using a water-cooled torch, check coolant flow, may be restricted
or coolant may be low.
Tungsten oxidation during cooling. Keep shielding gas flowing 10-15 seconds after arc stoppage (one second for each 10 amps of weld
current).
Tungsten melting back into cup (AC). If using pure tungsten, change to ceriated or lanthanated. If machine has Balance Control, adjust
setting towards maximum penetration (70-90). Increase tungsten size -Tungsten diameter may be too
small for the amount of current being used.
Tungsten melting into weld puddle. Use less current or larger tungsten. Use ceriated (AC), thoriated (DC), or lanthanated tungsten.
Touching tungsten to weld puddle. Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work
piece 1/16 to 1/8 in.
Inadequate or too much gas flow or Check flow rate (15 to 20 CFH) and gas type.
wrong gas type.
Incomplete weld circuit. Check work connection. Check all cable connections.
No shielding gas. Check for gas flow at end of torch. Check for empty cylinder or closed shut−off valve. Gas flow
should typically be set at 15 to 20 CFH.
Condensation on base metal. Line should be purged with Argon for a few minutes. Remove all condensation from base metal before
welding. Metals stored in cold temperatures will condensate when exposed to warm temperatures.
Loose fittings in torch or hoses. Tighten fittings on torch and all hoses.
Inadequate or too much gas flow. Adjust flow rate as necessary. Gas flow should typically be set at 15 to 20 CFH.
Defective gas hose or loose connec- Replace gas hose and check connections for leaks, cuts, or pin holes.
tion.
Contaminated or improper filler metal. Check filler metal type. Remove all grease, oil, or moisture from filler metal.
Base metal is contaminated. Remove paint, grease, oil, and dirt, including mill scale from base metal.
Shielding gas flow rate too low. Increase flow rate. Gas flow should typically be set at 15 to 20 CFH.
Improper tungsten size or cup size. Match tungsten size and cup size to joint being welded. General purpose tungsten size is 3/32 in.
diameter and 8 cup.
Tungsten contamination. Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work
piece 1/8 to 1/4 in.
Excessive rectification in arc. Increase travel speed. Increase balance control toward more penetration. Add filler metal.
Improper shielding gas. Change shielding gas - In some cases, when welding on 3/8 to 1/2 in. thick aluminum, Argon/Helium
is used.
Incorrect arc length. Use correct arc length. Adjust the torch so that the tungsten is off of the work piece 1/8 to 1/4 in.
Tungsten is contaminated. Remove 1/2 in. of contaminated tungsten and repoint tungsten.
Base metal is contaminated. Remove paint, grease, oil, and dirt, including mill scale from base metal.
Frequency set too low. On welders with adjustable AC frequency, increase frequency to give proper arc stability and direc-
tion. 100 to 180 Hertz is acceptable.
Improperly prepared tungsten With Squarewave and inverter machines, use pointed tungsten. Point will eventually round off after
welding.
Weld circuit polarity is incorrect. Check polarity switch on welder. Select DCEN (Direct Current Electrode Negative).
Tungsten is contaminated. Remove 1/2 in. of contaminated tungsten and repoint tungsten.
Arc too long. Shorten arc length. Lower torch so that the tungsten is off of the work piece no more than
1/16 to 1/8 in.
Base metal is contaminated. Remove paint, grease, oil, and dirt, including mill scale from base metal.
Improper arc length/tungsten in poor Lower the torch so that the tungsten is off of the work piece 1/16 to 1/8 in. Clean and sharpen tung-
condition. sten.
Improperly prepared tungsten. Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and wheel.
Light gray frosted appearance on end Remove 1/2 in. of tungsten and repoint tungsten.
of tungsten.
Improper tungsten preparation. With Squarewave and inverter machines, use pointed tungsten. Point will eventually round off after
welding.
Tungsten is contaminated. Remove 1/2 in. of contaminated tungsten and repoint tungsten.
Base metal is contaminated. Remove paint, grease, oil, and dirt, including mill scale from base metal.
Incorrect balance control setting. Increase balance toward more penetration. Normal Balance Control setting is 70 - 90.
Improper tungsten size and type. Select proper size and type. General purpose tungsten size is 3/32 in. diameter and ceriated or thori-
ated.
Excessive rectification in arc. Increase travel speed. Increase balance setting toward more penetration. Add filler metal.
Improper shielding gas flow. Gas flow should typically be set at 15 to 20 CFH.
Frequency set too low. Increase AC frequency on machines so equipped to stabilize and direct the arc. The higher the fre-
quency, the narrower and deeper the penetration.
Notes
229895
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.