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Tungsten Arc Gas shielded Welding

Basic Principles Collet Holder
When Tungsten Arc Gas
Shielded (TAGS ) welding, heat
Ceramic
is generated by an electric arc
formed between a Tungsten nozzle
Tungsten
electrode and the metal being
welded.
The Tungsten electrode is non Gas
consumable, i.e. when used shield
Arc
correctly it does not melt and
become part of the joint.
Additional metal may be added
using a filler rod.
The welding arc, electrode and
weld pool are shielded by an
inert gas, usually argon, which SHIELDING GAS
issues from a nozzle The main purpose of the shielding gas is to
surrounding the electrode. protect the weld and hot electrode from the
atmosphere in order to prevent oxidation.
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 Five Advantages over Manual Metal Arc welding

1. The arc is more concentrated giving deeper penetration.

2.Control of penetration is better, allowing the welder to achieve a

more consistent root bead profile.
3. The welder decided where and when to deposit additional filler
wire.

4. A wider range of metals and alloys can be welded. E.g..

Aluminium,Titanium, Copper and Nickel alloys.

5. No flux is required and there is no slag to control.

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 EQUIPMENT
Direct current power sources
The power source for TAGS welding should
D.C. Inverter Set
give a drooping characteristic.
The d.c welding supplies may be supplied from
a d.c. generator, a transformer rectifier or an
inverter set as shown.
D.C. Supplies at the arc are required when
welding:
•Carbon steels.
•Stainless steels.
•Copper and its alloys.
•Nickel and its alloys.
•Titanium alloys.
•Hardsurfacing with cobalt based alloys

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Power Sources
Alternating Current
Transformer rectifier set
A.C. may be supplied from:
An a.c. transformer set.
A transformer rectifier as
shown,which is capable of
supplying both a.c. or d.c.
An inverter which can supply
both a.c. and d.c.
A.C. Supplies at the arc are
required when welding:
•Aluminium & its alloys.
•Magnesium And its alloys
•Aluminium bronze.
•Cast iron.

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 Striking the arc

Scratch Start: When using d.c.it is possible to

strike the arc by touching the electrode onto the
work and withdrawing it to form an arc.
This can give unsatisfactory results as the
electrode point can be damaged or contaminated
and tungsten inclusions may be left in the weld. If
this is the only method provided the arc may be
initiated on a block of carbon and then transferred
to the work.

Lift Arc: Some welding sets are provided with a lift

arc facility. With this technique the electrode is
brought into contact with the work and current
switched on, this is a very low value of current until
the electrode is lifted from the work when the
current rises initiating the arc. this method reduces
the risk of electrode contamination and damage.
Rest the ceramic nozzle on the
work, rock forwards allowing the
tungsten to contact the work and
rock back to initiate the arc.

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 Striking the arc
Scratch Start
Scratch Start: When using
d.c.it is possible to strike the
DOUBLE TWICE arc by touching the electrode
CLICK TO ANIMATE onto the work and
withdrawing it to form an arc.
This can give unsatisfactory
results as the electrode point
can be damaged or
contaminated and tungsten
inclusions may be left in the
weld. If this is the only method
provided the arc may be
initiated on a block of carbon
and then transferred to the
work.

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 Striking the arc
Lift Arc Technique With this method the
power source supplies a
very low current when
DOUBLE TWICE the electrode is brought
CLICK TO ANIMATE into contact with the
work (typically one
amp.)
When the electrode is
lifted from the work the
current rises to its set
value.
The initial low
amperage prevents the
tungsten from sticking
to the work preventing
damage to the electrode
tip.

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 HIGH FREQUENCY START
This is the preferred method of arc starting when using
d.c. and is essential when using a.c.
The power source is fitted with a high frequency spark
generator. To initiate the arc the electrode is brought to
within about 5mm of the work and the foot-switch/trigger
is pressed, a high voltage high frequency spark jumps the
gap between the tungsten and the work ionising the arc
gap and the welding current flows across the gap forming
the arc.
A three position switch is provided.
•Continuous: When using a.c. the H.F. is continuous to
maintain arc stability.
•Off : permits touch starts only sometimes used when
working near sensitive electronic equipment.
• Start only:When d.c. is being used the high frequency
spark switches off when the arc is established.

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HIGH FREQUENCY START Striking the arc

DOUBLE CLICK This is the preferred

TO ANIMATE method of arc starting
when using d.c. and is
essential when using a.c.

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 Front Panel A.C. D.C TAGS Power Source

Post purge
Process Soft H.F Remote current 11
selector start Start control
 Suppressor Unit
TAGS power sources which can give an a.c. output are usually fitted with a
suppressor unit.
This is only used when welding with a.c. The function is to correct an
imbalance of current flow across the arc caused by the arc being between two
dissimilar metals e.g. Tungsten and Aluminium.

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Other features may include
Pulsed current. The Current is supplied in a series of high amperage pulses, a
low background current keeps the arc ionised during the pulse off periods.
Advantages: better control of penetration & bead shape, easier welding of thin
materials, reduced distortion.

Peak current

Amps Background
current

Time in milliseconds

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 Slope In & Slope Out

Slope in: On striking the arc current

builds up from a low value to the set
value, over a period of time which can
be pre-set with the control. Reduces
the risk of burn through when starting
on thin sheet.

TIME
Slope out At the end of the weld the
current can be set to decay to zero over a
pre-set period of time. This allows for
crater fill and reduces the risk of crater
cracks.

TIME
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 Other Features of TAGS Power Sources

Shielding gas pre-flow and post-flow ( pre purge and post-purge);

The pre-flow purges the weld area with shield gas prior to starting
the arc, this is fixed with most power sources.
Post- flow allows the shield gas to flow for a few seconds after
breaking the arc whilst the weld and tungsten cools. May be
adjustable, higher amperages require a longer post purge.
Remote footswitch control
When the footswitch is set to remote the current may be increased
or reduced by applying more or less pressure to the footswitch.
This is useful for filling the crater at the end of a weld or for
controlling heat build up especially when welding aluminium.
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WELDING TORCHES
TORCH COMPONENTS

SPLIT COLLET
COLLET HOLDER

CERAMIC
NOZZLE

END CAP
TUNGSTEN
ELECTRODE

TORCH HEAD

N.B. The torch may be fitted with a trigger switch or a footswitch

may be used.
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 WELDING TORCHES
Air cooled
Water cooled
These are normally used for currents
Water in
up to 150 amps.

Water cooled Gas in

For current above 150 amp. The

coolant is pumped first through the
torch head taking heat from the torch
and tungsten electrode, the water Water
then returns through the welding out
current cable, flowing between the
plastic insulation and the copper
conductor thus cooling the cable as Welding
well as the torch head. current in
Advantages

Higher currents can be used, thinner power cable is more flexible, electrode can be used
at higher amperage due to improved cooling

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 WATER COOLED FUSE

Whilst most modern water cooling systems will prevent current from being switched
on if the coolant is not flowing. Some older systems have a water cooled fuse fitted in
line with the welding current cable.
The purpose of this fuse is to prevent the torch from being damaged if the water
supply is interrupted or if the operator forgets to turn it on.

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 Gas Nozzles
These are usually made from a heat resisting
ceramic material.
The choice of size depends on a number of factors
such as:
Ceramic nozzles
•Current value.
•Electrode diameter.
•Joint type.
•Gas flow rate.
•Material being welded.
•Welding position.
Glass nozzle

Transparent gas nozzles

are available, these give a
better view of the arc
when joint access is
difficult
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Gas Lens

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Gas lens
Purpose
this focuses the gas
stream, giving a lammeller
column of gas which
permits:
Lower gas flow rates.
Better gas coverage.
Allows more electrode
extension.

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 Tungsten Electrodes
Electrodes for TAGS welding are made from Tungsten which melts at around
3400oC. Providing that maximum current is not exceeded and that correct polarity
is observed when using d.c. the electrode will not melt in the arc.

Types of Tungsten Electrode

Pure Tungsten: These may be used for any application but the types listed below give
better results.
Thoriated Tungsten: Recommended for d.c. welding. The addition of 1 to 2%
Thorium oxide maintains a sharp point on the electrode and increases it’s current
carrying capacity.
Zirconiated Tungsten: Recommended for a.c. welding. The addition of a small
percentage of Zirconium oxide improves arc stability and reduces the risk of Tungsten
inclusions in the weld.

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Thoriated TungstenElectrodes

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Electrode sizes and current ranges
Electrodes are normally available in 100 mm or 150 mm lengths.
The diameters range from 1.0 mm to 4.8 mm .
Although larger diameters are available for a.c.welding with high currents.
The choice of electrode diameter will depend on the type of current, polarity
( d.c. ), type of electrode and shielding gas.

Current carrying capacities

Electrod dia. Thoriated Thoriated Zirconitaed
mm d.c. negative d.c. positive a.c.
1.6 50 - 140 10 - 15 30 - 90
2.4 120 - 250 15 - 20 70 - 140
3.2 240 - 380 20 - 35 120 - 190
4.0 280 - 400 35 - 50 170 - 250
4.8 350 - 500 50 - 75 210 - 320

N.B. Too low a current results in an unstable arc.

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ELECTRODE POINT DIMENSIONS WHEN
A.C. WELDING
Electrode should be pre-ground as shown.

45o
D 1/2 x D

Prior to welding the the arc should be run on a piece of scrap

material to produce a balled end, this reduces the risk of tungsten
inclusions at the start of a weld.

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ELECTRODE POINT DIMENSIONS WHEN
D.C. WELDING
The point dimensions below are a general guide only and may
be modified to suit the job in hand.

Up to 3.2mm dia L = 3 x D

L
Above 3.2mm dia L = 2 x D

L
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 CORRECT METHOD OF GRINDING
ELECTRODES
Abrasive wheel

Ensure grinding marks

run lengthways along the
electrode taper

3000
RPM Electrode

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 EFFECT OF INCORRECT GRINDING OF ELECTRODES

Stray arcing due to hot

spots on electrode
Note! Grinding marks
running concentric with
electrode

It is important to grind the electrode lengthways so that the grind marks run along
the length of the taper and not across it otherwise stray arcing may occur when
welding in vee preparations.
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ELECTRODE STICK-OUT

This will vary according to the

type of joint, e.g. vee butt
preparations will need more
stick-out than square butt
welds.

3 to 6 mm

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 EFFECT OF ELECTRODE POLARITY

D.C. ELECTRODE POSITIVE

The electrode is at the

hot side of the arc, it
will overheat and
contaminate the weld
pool.the electrons are
flowing from the work
towards the electrode.
This condition gives a
cathodic cleaning effect.

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 EFFECT OF ELECTRODE POLARITY

D.C. ELECTRODE NEGATIVE

The electrode is at
the cool side of the
arc and does not
overheat.
The electrons are
flowing from
electrode to work.
( no cathodic
cleaning takes
place)

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EFFECT OF ELECTRODE POLARITY

ALTERNATING CURRENT

DOUBLE TWICE A.C. Changes its

CLICK TO direction of flow at
ANIMATE twice the frequency of
the supply I.e. 100
reversals per second.
Each time the electrode
becomes positive
cathodic cleaning takes
place.
When the electrode
becomes negative it
cools.
This condition is used
when welding
aluminium &its alloys.
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 SHIELDING GASES
Gas Colour
code
Application A B
A Argon Blue All, applications low arc voltage ,
good for thin sections.
B Helium + Brown Preferred gas shield for thick
Argon with blue sections of aluminium and copper,
band gives higher
arc volts than argon
C Argon + Blue with The preferred gas shield for stainless
Hydrogen red band Steels, the hydrogen gives improved
Protection from oxidation giving a
cleaner weld surface.
D Nitrogen, Grey with May be used as a cheap alternative
C
C D
Oxygen black to argon or helium when welding
free shoulder copper only
and white
spot

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 Shielding Gas Control Equipment

Regulator Flowmeter
REGULATOR
Purpose, to reduce cylinder pressure to
working pressure.
FLOWMETER
To control and indicate the amount of gas
flowing, in litres per/minute.
MAINTAINENCE
Check for leaks with soap water solution,
check threads and fittings for damage.

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 SHIELDING GAS FLOW RATES

Argon
When welding carbon steels up to Press gas purge
3mm thick a flow rate of 5 to 6 litres switch or
per minute is sufficient. When footswitch & set
vertical welding the flow rate may be flow rate with
increased slightly as argon is heavier control valve.
than air and will leave the joint area
more quickly.

CONTROL
VALVE

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 Filler Rods and Wires
Composition
Filler rods for TAGS welding should conform to BS En 440: 1995

When welding low carbon steel a filler rod designated G3Si2 should be
used.
This rod contains sufficient deoxidisers to prevent porosity.

Gas welding rods should not be used, as they do not contain sufficient
deoxidisers to prevent porosity.

Filler rods, which comply with BS 2901 grade A15, or 18 may still be
used.

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 FILLER ROD DIAMETER

The filler diameter to be used Filler diameters can be selected from the
will depend upon the material following range of sizes: mm
thickness, joint type, size of
fillet and current value. 0.5
0.8
Handling and storage
1.0
DO NOT 1.2

1. Store wires in damp or dirty conditions. 1.6

2. Handle them with greasy gloves or hands. 2.4

3. Allow different rods to become mixed up. 3.2

DO
1. Ensure that wires are correctly labelled and packaged.
2. Return unused rods to their correct packet.

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 Gas Economiser

Economiser’s may be Combined economiser flowmeter

fitted to some older
TAGS systems.
VALVE
When the torch is hung
on the hook the weight
of the torch closes a
valve shutting off the gas
supply.

HOOK

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 BACKING TECHNIQUES WHEN BUTT WELDING

Backing applied to the root of a butt joint may be required to either provide support
for the root run or to prevent oxidation.
The types of backing techniques available are as follows.

Temporary backing: The backing bar is usually made from a different

material to that being welded and it is removed on completion of the joint.
When welding carbon steels or stainless steels aluminium or copper may be used
these are good conductors of heat compared to steels. Carbon steel or stainless steel
may be used for aluminium and copper.

CLAMP

CHILL

BACKING BAR

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 BACKING TECHNIQUES WHEN BUTT WELDING
Permanent or Fusible Backing
The backing strip is often used when the joint is accessible from one side only, it can
also be used as an aid to assembly. The backing strip is made from the same material
as that being welded and is left in place after welding.

Tack Weld

Root run deposited and backing strip becomes part of joint

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 BACKING TECHNIQUES WHEN BUTT WELDING
Fusible inserts
When a controlled penetration bead is required and where access to the back of the joint is
impossible a root insert may be used, known as an EB insert. ( EB refers to the Electric
Boat Company ). Often used on pipe joints.
The insert is tacked first to one
component of the joint and then to the
other all tacks on the topside of the joint.
The root and the insert are then fused
together without the addition of filler rod.
When fusing the root the weld pool will
be seen to rise slightly indicating
complete fusion of the insert.

Before welding After welding

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 Applying a Backing Gas
Some metals such as stainless steels, nickel alloys and titanium require shielding gas to
be applied to the underside of a joint in order to prevent oxidation.

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 Method of back-purging a pipe butt joint

A commonly used flow rate when applying a backing gas is

4 litres/min.

Gas in
Connecting rod

Plug Gas out

The soft faced plugs are fitted when the joint is aligned for tacking and pulled
out on completion of welding, the assembly is then used for the next joint.

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 CLOSED SQUARE BUTT WELD IN 3MM THICK
LOW CARBON STEEL
1.Establish the arc at the right-hand end of the joint with the electrode held at an
angle of 70o - 80o.
2.Immediately fusion to the root of the joint is obtained add filler metal to prevent
excessive fusion of parent metal.
3.Commence leftwards movement without weaving of torch.
4.Co-ordinate addition of filler metal and rate of travel so as to maintain fusion to
the root and build up the weld to a slightly convex profile.
5. Add filler metal immediately if excessive penetration seems imminent.

Material 1 piece low carbon steel.

100mm x 150mm x 3mm thick
Preparation Clean & remove oxide.
Electrode 2.4mm thoriated
Shielding Argon 5 litres/min
gas
Nozzle 10mm
bore
Current 90 – 100 A
Filler 1.6mm G3Si2 44
 POSITIONAL WELDING
Only slight changes are necessary when carrying out positional welding, e.g. a slight
increase in slope angle and the shielding gas flow-rate may be increased to overcome
the effects of gravity.

VERTICAL UPWARDS

Overhead

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