GAS TUNGSTEN ARC WELDING

INTRODUCTION
Gas tungsten arc welding (GTAW) is an arc welding process that uses an arc between a non-
consumable tungsten electrode and the work-piece to establish a weld pool.
The process is used with shielding gas.
The process has been called non-consumable electrode welding and is very often referred to as
TIG (tungsten inert gas) welding.

The four basic components common to all GTAW setups are a torch, the electrode, a welding
power source, and shielding gas.

POWER SOURCES
Transformer- AC- constant current
Rectifier- DC- constant current

PROCESS VARIABLES
The principal variables in GTAW are arc voltage (arc length), welding current, travel speed, wire
feed speed and shielding gas.
The amount of energy produced by the arc is proportional to the current and voltage. The amount
of energy transferred per unit length of weld is inversely proportional to the travel speed.
The arc shielded with helium is generally hotter and more penetrating than the argon shielded
arc.
Welding Current
Gas tungsten arc welding can be used with direct current (dc) or alternating current (ac)
Alternating current provides a cathodic cleaning action during the electrode positive portion of
the ac cycle, which removes refractory oxides from the metal surfaces. This cleaning action,
known as sputtering, eliminates nearly all refractory oxide film from the weld pool surface and
facilitates superior welds. In this case, argon must be used for the shielding because sputtering
does not occur with helium. So AC current used for welding Al.

Arc Voltage
Arc voltage, which is generally proportional to arc length, is a dependent variable that is affected
in decreasing amounts by the following:
1. The distance between the tungsten electrode and the work-piece,
2. Welding current,
3. Type of shielding gas,
4. The shape of the tungsten electrode tip, and
5. Ambient air pressure.
Arc length is an important variable with GTAW because it affects the width of the weld pool
(pool width is proportional to arc length) and to a lesser extent, penetration and shielding
coverage.
When using DCEN in mechanized welding with a relatively high current, it is possible to use the
arc to depress the weld pool and submerge the electrode tip below the surface of the work-piece
to produce deeply penetrating but narrow welds at high speeds without shorting out the tungsten
electrode. This technique, which requires good control of arc voltage and arc length, is
sometimes referred to as buried arc.
Travel Speed
Travel speed affects both the width and penetration of a gas tungsten arc weld.
Classification of Electrodes
Tungsten electrode classifications are based on the chemical composition of the
electrode and also shows the color identification system for the various classes of tungsten
electrodes.

The EWTh-1 and EWTh-2 electrodes were designed for DCEN applications. They maintain a
sharpened tip configuration during welding, which is the desired geometry for DCEN welding
operations.
Electrode Tip Configurations
With ac welding, pure or zirconiated tungsten electrodes form a hemispherical (balled) end.
In general, as the included angle increases, the weld penetration increases and the width of the
weld bead decreases.
FILLER METALS
Filler metals for GTAW are available in most alloys in the form of cut lengths (rods), usually
0.91 meter (m) (36 in.) long for manual welding .
Low Alloy (Solid) Electrode Classification ER70S-2, ER70S-3, etc.
SHIELDING GASES
Argon and helium (used separately or together) are the two most common types of inert gas used
for shielding.
Argon is used more extensively than helium for shielding because argon offers the following
advantages:
1. Smoother, quieter arc action;
2. Reduced penetration;
3. Cleaning action when welding materials such as aluminum and magnesium;
4. Lower cost and greater availability;
5. Lower flow rates for good shielding;
6. Better cross-draft resistance; and
7. Easier arc starting
Recommended Gas Flow Rates
Typical shielding gas flow rates are 7 to 16 liters per minute (L/min) for argon and 14 to 24 L/min. for
helium.
DISCONTINUITIES AND DEFECTS
1. Porosity
2. Incomplete fusion
3. Incomplete joint penetration
4. Oxidation of S/S weld bead
5. Tungsten inclusions
Causes of Tungsten Inclusions
1. Contact between:
Tungsten and base metal
Tungsten and filler metal
1. Excess current
2. Excess tungsten extension
3. Improper tungsten tip grinding
4. Inadequate shielding gas flow rates or excessive
GTAW Advantages
1. High quality welds /Good appearance
2. No slag
3. Very little, if any, post-weld cleaning required
4. Autogenous welding (welding without filler metal /Good for thin materials such as AL)
5. Can be automated
GTAW Limitations
1. High skill factor required
2. Low deposition rate / Low productivity
3. Lower productivity
4. Higher initial cost of the equipment
5. Shielding gas expensive
6. Purging gas expensive to Prevent Oxidation in the root area during welding stainless steel,
titanium and other corrosion-resistant materials.
WELDING PROBLEMS AND REMEDIES