Professional Documents
Culture Documents
591 Tig 5
591 Tig 5
1
The ER aluminum rod and wire are designed to produce high quality welds in Types 5052, 5154, 5356,
6061, 6063, 5083, and 5086 aluminum plate. Welds made with the ER 5356 have a much greater
resistance to hot-short cracking, particularly in low-magnesium alloys or between dissimilar metals. The ER
5356 produces a fluid weld puddle for easy handling and superior weld quality.
3. WELDING CONDITIONS
Fundamentals
of TIG
Welding
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
2
TIG HAND WELDING OF STAINLESS STEEL
Fundamentals
of TIG
Welding
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
*Conditions very similar for HASTELLOY B & C and other similar alloys. NOTE: for aluminum heavier than 1/2 in., argon-helium
** Welding speed for flat position. mixtures provide greatly improved performance.
+ These are minimum recommended gas flows.
Higher flow may be necessary to assure weld quality. •Consult the torch instruction booklet for the maximum
current ratings of the torch and for sizes and part
numbers of available cups or nozzles.
3
Stainless Steel
1. PRINCIPAL WELDABLE TYPES OF STAINLESS STEEL
AUSTENITIC - (Cr-Ni)
%C %Cr %Ni % Others Rod to Use
Type 201 0.15 max. 17.0 4.0 Mn 6.5 ER 308
Fundamentals Type 202 0.15 max 18.0 6.0 Mn 6.5 ER 308
of TIG
Welding Type 301 T 0.08 - 0.20 17.0 7.0 ER 308
Type 302 0.08 - 0.20 18.0 8.0 ER 308
Aluminum
Type 304, 0.08 max. 18.5 8.5 ER 308
Prep for And Its Alloys 304 ELC 0.03 max. 18.5 8.5 ER 308L
Welding Type 308 0.08 max. 20.0 11.0 Mn 2.00 max. ER 308
Stainless
Steel Type 309 0.20 max. 24.0 13.0 ER 309
Type 310 0.25 max. 25.0 20.0 ER 310
Magnesium
Alloys Type 316, 0.10 max. 17.0 12.0 Mo 2.5 ER 316
Safe
Practices 317 0.10 max. 17.0 14.0 Mo 3.5 or 317
Copper And
Its Alloys Type 318 0.10 max. 17.0 12.0 Mo 2.5, Cb 10xC ER 318
Type 347 0.10 max. 18.5 10.0 Mn10x C ER 347
Plain Carbon &
Handling Low Alloy Steels FERRITIC - (Straight Cr)
the Torch TIG Welding %C %Cr % Others Rod to Use
Of Pipe Type 430 0.12 max. 14.0 -18.0 ER310*, 309
Nickel, Monel, Type 446 0.35 max. 26.0 ER310*, 309*
Welding And Inconel
Data Welding Diff.
MARTENSITIC - (Straight Cr)
Metals %C %Cr % Others Rod to Use
Type 410 0.15 max. 12.0 ER 410
Type 510 0.10 5.0 ER 310*, 309*
Type 502 0.10 max. 5.0 ER 310*, 309*
4
2. SPECIAL PRECAUTIONS
1. Air hardening: Preheat to 400 to 500 deg. F. to avoid cracking. Follow by annealing to avoid excessive
hardness and cracking. Follow recommendations of manufacturer.
Use Type 310 or 809 rod to give ductile weld metal.
5
3. WELDING CONDITIONS
Fundamentals
of TIG
Welding
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
6
TIG HAND-WELDING OF DEOXIDIZED COPPER
Fundamentals
of TIG
Welding
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
*(Copper)
+These are minimum recommended gas flows. Higher flow may be necessary to assure weld quality.
Consult the torch instruction booklet for the maximum current ratings of the torch and for sizes and part numbers of available cups
or nozzles.
7
Magnesium Alloys
1. WELDABLE ALLOYS
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
8
2. WELDING CONDITIONS
MANUAL WELDING OF MAGNESIUM (AZ31B & HK31A ALLOYS) Using A.C.H.F.
Welding Current
Amperes* Shielding
Thick- Type of Flat Position Welding Rod Gas Flow
ness in. Weld (1) HK31A AZ31 B (2) Size, in. Argon Helium Remarks
0.040 Butt 40 35 3/32, 1/8 10 25 Backup
Fundamentals 0.040 Butt 30 25 3/32, 1/8 10 25 No backing
of TIG
0.040 Fillet 40 35 3/32, 1/8 10 25
Welding
0.064 Butt 55 50 3/32, 1/8 10 25 Backup
0.064 Butt & 35 30 3/32, 1/8 10 25 No backing
Aluminum
Prep for And Its Alloys Corner
Welding 0.064 Fillet 55 50 3/32, 1/8 10 25
Stainless
Steel 0.081 Butt 75 65 1/8 10 25 Backup
0.081 Butt, Corner 45 40 1/8 10 25 No backing
Magnesium
Alloys & Edge
Safe
Practices 0.081 Fillet 75 65 1/8 10 25
Copper And
Its Alloys 0.102 Butt 95 85 1/8 20 30 Backup
0.102 Butt, Corner 70 60 1/8 20 30 No backing
Plain Carbon & & Edge
Handling Low Alloy Steels
0.102 Fillet 95 85 1/8 20 30
the Torch TIG Welding 0.128 Butt 110 100 1/8, 5/32 20 35 Backup
Of Pipe
0.128 Butt, Corner 80 70 1/8, 5/32 20 35 No backing
Nickel, Monel, & Edge
Welding And Inconel
0.128 Fillet 110 100 1/8, 5/32 20 35
Data Welding Diff. 3/16 Butt 155 140 1/8, 5/32 20 35 1 pass
Metals
3/16 Butt 110 100 1/8, 5/32 20 35 2 passes
1/4 Butt 200 180 5/32, 3/16 25 50 1 pass
1/4 Butt 125 115 5/32 20 35 2 passes
3/8 Butt 270 250 5/32 , 3/16 25 50 1 pass
3/8 Butt 160 140 5/32, 3/16 25 50 2 passes
1/2 Butt 330 310 3/16 25 50 2 passes
3/4 Butt 450 420 3/16, 1/4 35 75 2 passes
*Current values given for butt joint welding are with backing plate. Slightly lower values used for welding without a backing plate.
9
3. PROCEDURES
(a) Careful cleaning of the workpiece is always required since magnesium oxidizes readily.
(b) A short arc length (1/16 in. or less), must be used to produce a bright, shiny weld. Longer arcs will
leave the weld surface dark and cloudy looking.
(c) When using filler metal, hold the rod at a small angle (less than 10 deg.) to the plate, with the end of
Fundamentals the rod touching the leading edge of the puddle. As the torch is moved along the joint, it melts off small
of TIG
Welding
pieces of the filler rod. No ”dipping” motion of the rod is necessary.
(d) To minimize distortion and stress corrosion, magnesium welds should be stress-relieved after
Aluminum welding as follows:
Prep for And Its Alloys
Welding Alloy Temp. - Deg. F. Time - Min.
Stainless
Steel
AZ81B-0 500 15
Magnesium
Safe Alloys AZ31B-H24 300 60
Practices HK81A is not stress corrosion sensitive and requires no thermal treatments after welding for this purpose.
Copper And
Its Alloys Straightening may be performed at 6000F (1 hr. maximum).
Plain Carbon & (e) Tensile Strength of magnesium welds is approximately 90 - 100% of the base metal strength of AZ31B
Handling Low Alloy Steels
alloy and 80-90% of HK31A alloy.
the Torch TIG Welding
Of Pipe (f) Consult your metal supplier if additional welding details are required.
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
10
Copper and Its Alloys
1. GENERAL
(a) The weldability of each copper-alloy group depends largely upon the alloying elements. For this reason,
we do not attempt to give one set of welding conditions applicable to all groups. Each will be discussed
Fundamentals separately.
of TIG
Welding (b) DCSP is generally used for welding most copper alloys. However, ACHF or DCRP is recommended for
beryllium copper or for copper alloys less than 0.040-in. thick.
Aluminum
Prep for And Its Alloys (c) Where flux is recommended, never use a flux containing fluorides. The intense heat of the arc will
Welding vaporize the fluorides which, if inhaled in appreciable quantities, will irritate the lungs.
Stainless
Steel
(d) Always provide good ventilation when welding copper or any copper alloy. This is particularly
Magnesium important when welding beryllium copper or when using beryllium copper welding rod. The dusts, fumes,
Safe Alloys and mist of beryllium compounds in virtually every form are highly toxic. The American Conference of
Practices Governmental Industrial Hygienists has adopted a threshold limit value - TWA = 0.002 mg/m3 . The ACGIH
Copper And
Its Alloys has also listed beryllium as an industrial substance suspect of carcinogenic potential for man (refer to 1983-
Plain Carbon & 84 edition ACGIH). Because of this, extreme precautions should be taken to reduce the dusts, fumes, and
Handling Low Alloy Steels mists to zero. An effective high-velocity ventilating system should be used regardless of the degree of
the Torch TIG Welding
contamination. The welding operator should also be protected with clothing, gloves, and a mask of an
Of Pipe approved type.
Nickel, Monel,
Welding And Inconel
Data 2. ELECTROLYTIC COPPER
Welding Diff.
Metals
Due to the cuprous oxides contained in electrolytic copper, there is at present no known welding method that
can produce sound, high-strength welds in this material. Electrolytic copper is sometimes welded when
tensile strength requirements are only 19,000 psi or less, although porosity still occurs. Approximately the
same welding conditions are used as those recommended for deoxidized copper below.
11
3. DEOXIDIZED COPPER
(a) Unlike electrolytic copper, this grade does not contain enough oxygen to cause oxide embrittlement or
porosity if reasonable care is exercised during welding operations. Also, little change in electrical resistance
occurs across the joint. Deoxidized copper is the type most widely used for fabrication by welding. The
tensile strength of a good, sound weld is about 30,000 psi.
(b) Welding Technique: Workpieces thicker than 1/4 inch should be preheated to approximately 300-500
Fundamentals
of TIG degrees F. prior to welding. A forehand welding technique will produce the best results. Flux is required for
Welding thick sections, and must be applied to both the area being welded and the rod.
(c) Welding Conditions - See Chart on Page 14.
Aluminum
Prep for And Its Alloys
Welding
Stainless 4. COPPER-SILICON ALLOYS (”EVERDUR”, ”HERCULOY”, ETC.)
Steel
Magnesium (a) General: Excellent welds are made in these alloys without requiring flux. Plates up to 1/4 inch thick are
Safe Alloys
generally prepared with a square edge. Forehand welding technique with DCSP is generally recommended
Practices for materials thicker than 0.05 in. On lighter material, ACHF should be used for best weld results. Where
Copper And
Its Alloys
welding rod is required, ERCuSi-A Silicon Bronze Rod is recommended.
Plain Carbon &
Handling Low Alloy Steels
5. ALUMINUM BRONZE
the Torch TIG Welding
Of Pipe (a) General: No flux is required; ACHF will produce the best weld results; a forehand welding technique,
Nickel, Monel, with an aluminum bronze rod should be used. Aluminum bronze rod also provides good wear-resistance
Welding And Inconel surfaces when deposited on steel, cast iron, copper, and other metals.
Data Welding Diff.
Metals
(b) Welding Conditions
Plate Welding Argon Flow
Thick Current at recommended Electrode Number
in. Edge Prep. Amperes 20 psi Diameter of
ACHF cfh in. Passes
12
Fundamentals
of TIG BUTT TEE
Welding
BUTT
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
BUTT LAP INSIDE CORNER
Practices
Copper And
Its Alloys
OUTSIDE CORNERS
13
Fundamentals
of TIG
Welding
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
14
6. OTHER COPPER ALLOYS
The table below gives the basic recommendations for some of the less commonly welded copper alloys.
Welding conditions not specified below will, in general, approximate those given for deoxidized copper.
Type of Welding
Fundamentals Welding-Current Flux Technique Rod
of TIG
Welding Red Brass DCSP on thicknesses BRAZO Forehand ERCuSi-A
Zinc Bronze greater than 0.050-in.
Aluminum
And Its Alloys Low Zinc Brass ACHF on
Prep for
Common Brass thinner material.
Welding
Stainless Muntz Metal
Steel
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
15
Plain Carbon and Low Alloy Steels
1. WELDABLE MATERIALS
Two general types of plain carbon or low alloy steels are ”killed” steel and ”rimmed” steel. The former is
deoxidized during the refining process; little difficulty is experienced in welding this type. In the making of
Fundamentals
rimmed steel, however, deoxidation is incomplete. When this type of steel is subsequently melted in the
of TIG welding operation, gases are given off and can be a major cause of porosity if proper care is not exercised.
Welding Proper care can be taken by using ER 70S-2 triple deoxidized wire.
Aluminum
Prep for And Its Alloys 2. WELDING RODS
Welding
Stainless
Steel For welding most low carbon steel, ER 70S-2 or ER 70S-7 rod is used. For low-alloy high strength steels,
Magnesium ER 80S-D2 or ER 100S-1, ER 120S-1, or ER 140S-1 wire can be used. Alloy losses during welding will be
Safe Alloys negligible.
Practices
Copper And Thickness Amperes Suggested Average
Its Alloys
(in.) DCSP Rod Size Welding Speed Argon Flow
Plain Carbon & (in.) (I.P.M.) C.F.H.
Handling Low Alloy Steels
the Torch TIG Welding 0.035 100 1/16 12-15 8-10
Of Pipe
0.049 100-125 1 /16 12-18 8-10
Nickel, Monel, 0.060 100-140 1/1 6 12-18 8-10
Welding And Inconel 0.089 140-170 3/32 12-18 8-10
Data Welding Diff. 0.125 150-200 1/8 10-12 8-10
Metals
16
TIG Welding of Pipe
The chief advantage of TIG welding for the fabrication of piping systems is that the welds are smooth, fully
penetrated, and free from obstructions or crevices on the inside. Also, TIG welds are stronger and more
resistant to corrosion than welds made by any other process.
Fundamentals The brief instructions contained here are written for the standard vee joint with a bevel of 37 degrees on
of TIG each side, a nose of 1/16 in., and a spacing of 1/16 in. to 3/32 inch. The operator should practice welding in
Welding the flat position, or on a rolled joint, until the technique has been acquired.
Aluminum
Prep for And Its Alloys 1. ROOT PASS WELDING
Welding
Stainless
Steel After the joint has been properly tacked and put in position, the arc is struck on the side and carried down to
the bottom of the joint. Filler metal is then added until the puddle bridges over the joint. Control of
Magnesium
Alloys penetration is the most important factor in successful pipe welding. Such control can be obtained only by
Safe
Practices repeated practice. After the puddle bridges the joint, the arc is held on the puddle for a moment. Then the
Copper And puddle flattens out and becomes wedge shaped, straight across the front, and with rounded corners at the
Its Alloys
rear. When this takes place, the puddle has fully penetrated the joint.
Plain Carbon &
Handling Low Alloy Steels In general, the same technique is used for welding in the horizontal-fixed position. However, the puddle must
the Torch TIG Welding
be controlled more closely to prevent sag when welding in the overhead position. In the vertical-fixed
Of Pipe position, the puddle is formed on the upper side and kept above the center line of the joint. This will prevent
undercutting of the top side of the bead and avoid the tendency for the puddle to sag due to gravity.
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
2. FILLER PASS WELDING
Weave beads, produced by weaving the torch across the joint, can be used on carbon and low-alloy steel in
the rolled or horizontal-fixed position. Stringer beads, laid parallel to the joint, are used for welding stainless
steel pipe since there is less tendency toward carbide precipitation. Stringer beads are recommended for
welding all carbon and low alloy pipe in the vertical-fixed position. The advantage of using weave beads, in
the rolled or horizontal-fixed position, is that it requires less time to complete the welds.
17
3. FINISH PASS WELDING
Finished welds should be 1/8 in. wider than the joint and evenly spaced on either side. Reinforcement
should be about 1/16 in. above the surface of the pipe. The weld edges should be straight, without any
undercutting. Weave beads can be used to make the finish pass on carbon or low-alloy steel pipe in the
rolled or horizontal-fixed position. Stringer beads are required for stainless steel heavy wall pipe in all
positions, and also for carbon and low-alloy pipes in the vertical-fixed position as well.
Fundamentals
of TIG
Welding
Aluminum
Prep for And Its Alloys
Welding
Stainless
Steel
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
18
Nickel, Monel, and Inconel
WELDING CONDITIONS
Magnesium
Safe Alloys
Practices
Copper And
Its Alloys
Nickel, Monel,
Welding And Inconel
Data Welding Diff.
Metals
19
Welding Different Metals
Stainless Steel to Cast Iron DCSP ERCuSi-A Direct welding arc on the rod -
not on cast iron