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Guidelines For Gas Tungsten Arc Welding (GTAW)
Guidelines For Gas Tungsten Arc Welding (GTAW)
201310
Processes
TIG (GTAW) Welding
Guidelines For
Gas Tungsten Arc
Welding (GTAW)
www.MillerWelds.com
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 PRINCIPLES OF GAS TUNGSTEN ARC WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Process Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Selecting A GTAW Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Typical GTAW Welding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 GAS TUNGSTEN ARC WELDING (GTAW)
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Typical GTAW Welding Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING . . . . . . . . . . . . . .
4-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . . .
4-2. Preparing Tungsten Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 GTAW WAVEFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 ARC SHAPING CAPABILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Arc Starting With Different Polarities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Balance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. AC Frequency Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Independent Amperage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Frequency Adjustment Control - 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Frequency Adjustment Control - 200 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 TIG SHIELDING GASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Shielding Gases For TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 GUIDELINES FOR GTAW WELDING (TIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Lift-Arc And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Suggested Inverter Power Source Starting Parameters For Various Aluminum Joints . . . . . . . . . . . . .
8-4. TIG Welding Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 GTAW TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
5
6
7
7
8
8
9
10
12
12
12
12
12
13
13
14
14
15
15
16
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19
Protect yourself and others from injury read, follow, and save these important safety precautions and operating instructions.
D Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
READ INSTRUCTIONS.
D Read and follow all labels and the Owners
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owners
Manuals, industry standards, and national, state, and local
codes.
D
D
D
D
D
D
D
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
5
4
3
1
2
3
4
5
6
7
Work Clamp
Torch
Coolant Out Hose
Coolant In Hose
Cooling System
Shielding Gas
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 information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust contains low-level
radioactive material. Properly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flammables away.
Workpiece
3
2
4
90
1
Work Clamp
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
tungsten
Guidelines:
1015
Direction of Travel
4
5
6
1025
1/16 in.
3/16 in.
Bottom View Of Gas Cup
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)
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
AC Argon
Up to 25
Up to 20
15-40
15-35
25-85
20-80
Electrode Diameter
50-160
50-150
130-250
135-235
250-400
225-360
400-500
300-450
500-750
400-500
750-1000
600-800
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.
Application Notes
Good allaround tungsten for both AC and DC welding.
* Color may vary depending on manufacturer, please refer to manufacturers guide for color designation.
Preparing Tungsten For DC Electrode Negative (DCEN) Welding or AC Welding With Inverter Machines
1
Grinding Wheel
Radial Grinding
Causes Wandering Arc
Tungsten Electrode
Flat
Straight Ground
2-1/2 Times
Electrode Diameter
2
4
Ideal Tungsten Preparation Stable Arc
Tungsten Electrode
Balled End
1 1-1/2 Times
Electrode Diameter
AC Sine Wave
Weld Sample
Time
40.0
30.0
+
Amperage
Current
20.0
10.0
0.0
10.0
20.0
Time
1/60 Second
30.0
40.0
Zero Crossover
Current
+
0
Current
+
0
1
2
Conventional Squarewave AC
Weld Sample
Time
40.0
30.0
10.0
Current
Amperage
20.0
0.0
10.0
20.0
30.0
40.0
Preheats tungsten
Repeatable starting
Repeatable starting
No cleaning on starts
No damage to tungsten
Acceptable for AC
. Arc shaping capabilities are enhanced by improved balance control, AC frequency control, and independent amperage control.
6-2. Balance Control
1
More EP Time
More Cleaning.
2
More EN Time
Less Cleaning.
1
Low AC Frequency
High AC Frequency
More EP Amperage
More EN Amperage
AC Waveform
Weld Sample
+
Current
1/60th of
a second
AC Waveform
Weld Sample
+
Current
1/200th of
a second
D Argon/Helium Mixtures
ARGON
ARGON/HELIUM MIXES
HELIUM
Travel Speed
Penetration
Reduced penetration
Increased penetration
Cleaning
Arc Starting
Arc Stability
Arc Cone
Arc Voltage
Flow Rate
Cost
TIG Electrode
Workpiece
Application:
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
HF Start
12
Touch
Seconds
Application:
HF start is used for the DCEN
GTAW process when a non-contact arc starting method is required.
Welding direction
2. Tilt Tourch
1. Form Pool
Welding direction
2. Tilt Tourch
1. Form Pool
15
4. Remove Rod
162 002-B
8-3. Suggested Inverter Power Source Starting Parameters For Various Aluminum Joints
Weld
Joints
Amperage Balance
Frequency
Base
Base
Filler
Filler Tungsten Tungsten Shielding Gas Flow
Material Material
Rod
Alloy Type
Diameter Gas
Alloy
Thickness Diameter
Butt
Joint
90-120
65-75%
60-120 Hz
6061
1/8 in.
1/8 in.
5356
2%
Ceriated
3/32 in.
Argon
15-20 CFH
T-Joint
100-125
70-75%
100-200 Hz
6061
1/8 in.
1/8 in.
5356
2%
Ceriated
3/32 in.
Argon
15-20 CFH
Lap Joint
90-110
70-75%
100-150 Hz
6061
1/8 in.
1/8 in.
5356
2%
Ceriated
3/32 in.
Argon
15-20 CFH
Corner
Joint
80-90
65-70%
100 Hz
6061
1/8 in.
1/8 in.
5356
2%
Ceriated
3/32 in.
Argon
15-20 CFH
Butt Joint
. To
90
70
20
. To
40
Torch Position For
Making a T-Joint
70
20
20
Lap Joint
. To
70
20
30
Corner Joint
. To
90
70
20
3
3
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
2
1
2 To 3 in.
(51-76 mm)
2
1
S-0057-B
Vise
the cause.
Weld Joint
Hammer
Remedy
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.
Change tungsten - General purpose tungsten size is 3/32 in. diameter at a maximum of 235 amps.
Air-cooled torches get very warm. If using a water-cooled torch, check to make sure circulator is
turned on then check coolant flow. Coolant flow may be restricted or coolant may be low.
Keep shielding gas flowing 10-15 seconds after arc stoppage (one second for each 10 amps of weld
current).
If using pure tungsten, change to ceriated or lanthanated. If machine has Balance Control, adjust
setting towards Max Penetration (70-90 percent).
Increase Tungsten size -Tungsten diameter may be too small for the amount of current being used.
Remedy
Use less current or larger tungsten.
Use ceriated (AC, DC), thoriated (DC), or lanthanated tungsten.
Keep tungsten from contacting weld puddle. Raise the torch so that the tungsten is off of the work
piece 1/16 to 1/8in.
Remedy
Check flow rate (15 to 20 CFH) and gas type.
Remedy
No shielding gas.
Remedy
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.
Adjust flow rate as necessary. Gas flow should typically be set at 15 to 20 CFH.
Replace gas hose and check connections for leaks, cuts, or pin holes.
Probable Causes
Contaminated or improper filler metal.
Remedy
Check filler metal type. Remove all grease, oil, or moisture from filler metal.
Remedy
Remove paint, grease, oil, and dirt (including) mill scale from base metal.
Remedy
Tungsten contamination.
Remedy
Increase travel speed. Increase balance control toward Max Penetration. Add filler metal.
Change shielding gas - In some cases, when welding on 3/8 to 1/2 in. thick aluminum, Argon/Helium
is used.
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 paint, grease, oil, and dirt (including mill scale) from base metal.
On welders with adjustable AC frequency, increase frequency to give proper arc stability and
directional control. 100 to 180 Hertz is acceptable, 120 Hz is recommended.
Remedy
Check polarity switch on welder. Select DCEN (Direct Current Electrode Negative).
Tungsten is contaminated.
Shorten arc length. Lower torch so that the tungsten is off of the work piece no more than
1/16 to 1/8 in.
Check tungsten type or size.
Remove paint, grease, oil, and dirt (including mill scale) from base metal.
Remedy
Lower the torch so that the tungsten is off of the work piece 1/16 to 1/8 in.
Clean and sharpen tungsten.
Check tungsten type or size.
Grind marks should run lengthwise with tungsten, not circular. Use proper grinding method and wheel.
Remedy
Tungsten is contaminated.
Remove paint, grease, oil, and dirt (including mill scale) from base metal.
Increase balance toward Max Penetration. Normal Balance Control setting is 70 - 90.
Select proper size and type. General purpose tungsten size is 3/32 in. diameter and ceriated or thoriated.
Increase travel speed. Increase balance setting toward Max Penetration. Add filler metal.
229895
Notes
Owners Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
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and Parts)
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201301