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Gas Tungsten Arc Welding: by L D Poyyara
Gas Tungsten Arc Welding: by L D Poyyara
By L D Poyyara
GTAW
• Fusion Welding Process
• Arc Between Non-Consumable Tungsten
Rod And Work
• Arc & Weld Pool Shielded By Argon
• Filler Wire Separately Added To Weld Pool
• Welding Torch & Tungsten Rod Cooled by
Flow OF Argon / Cooling Water
Shielding Gas
• Inert Gas - Argon , Helium
• Common Shielding Gas – Argon
• When Helium Is Used – Called “Heli – Arc” Welding
• When Argon Is Used – Called “Argon Arc” Welding
• Inert Gas Prevents Contamination Of Molten Metal
• It Prevents Oxidation Of Tungsten Rod
• It Ionizes Air Gap and Stabilizes Arc
• It Cools Welding Torch & Tungsten Rod
Equipment & Accessories
Pressure Regulator
Flow Meter
Tungsten Rod
Argon Gas In
Cooling Water In Solenoid
Collet Valve Argon Cylinder
Gas Lens
HF Unit &
Welding Cable & Cooling Water Cooling
Ceramic Cup Water In Tube System
Cooling Water Out
Argon Shielding
Arc
High Frequency
+ Connection
Work
• Thyrester – DC
• Motor Generator – DC
• Rectifier – DC
• Drooping Characteristic
V
V1
Vertical
V2
Curve
A
A1 A2
High Frequency Unit
• Provides High Voltage Electric Energy With Very
high Frequency – 10000 Cycles / Sec.
When M/c On
• Power source gets energized
• Pump starts pumping cooling water to torch
When Pedal Switch Pressed with tungsten rod held close to BM within 3mm
• Solenoid valve opens, Argon starts flowing
• After 5 seconds of pre-purging, high Frequency current jumps from tungsten
rod generating sparks
• Immediately welding current makes arc across tungsten rod and work
through the HF sparks.
• High frequency gets cut off from the system when welding arc is initiated and
welding is started.
When Pedal Released without lifting the torch
1 Current gets cut off, Arc extinguishes, Gas flow continues as post purging.
2 Gas flow remains for few more seconds before it stops.
3 Torch to be lifted only after post purging stops
Argon Gas Cylinder- Pressure
Regulator + Flow Meter
• Regulator Regulates
Flow Meter
Cylinder Pressure to
Flow Regulator Working Pressure
Pressure Regulator
Connection To Torch • Flow Meter Controls
Flow Rate
Argon Cylinder
Shielding Gas
• Argon - Purity 99.99%
• Head Screen
• Hand gloves
• Chipping Hammer
• Wire Brush
• Spanner Set
Tungsten Rod
Tungsten Rod
crack
Lack Of Fusion
Cause Remedy
1) Inadequate Current 1) Use Right Current
2) Wrong Torch angle 2) Train /Qualify welder
3) Improper bead placement 3) Train/Qualify Welder
Lack Of Fusion
Porosity
Cause Remedy
1) Impure Argon Gas 1) Replace Argon Cylinder
2) Argon Leak Within Torch 2) Replace Leaking Torch
3) Defective Filler Wire 3) Replace Filler Wire
4) Wet surface of BM 4) Clean & Warm BM
5) Rusted / Pitted Filler wire 5) Clean Filler Wire
6) Improper Flow Of Argon 6) Provide Gas lens
Porosity . .
Undercut
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Voltage 2) Reduce Arc length
3) Improper Torch angle 3) Train & Qualify the Welder
Under cut
Lack Of Penetration*
Cause Remedy
1) Excess Root Face 1) Reduce Root Face
2) Inadequate Root opening 2) Increase Root Opening
3) Over size Filler Wire 3) Reduce Filler Wire size
4) Wrong Direction of Arc 4) Train / Qualify Welder
5) Improper bead placement 5) Train / Qualify Welder
6) Improper weaving technique 6) Train & Qualify Welder
* Applicable to SSFPW
LOP
Excess Penetration*
Cause Remedy
1)Excess root opening 1) Reduce root gap
2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase Root face
4) Excess Weaving 4) Train Welder
5) Wrong Direction Of Arc 5) Train Welder
* Applicable to SSFPW
Excess Penetration
Overlap
Cause Remedy
1) Wrong Direction Of Arc 1) Train & Qualify Welder
2) Inadequate Current 2) Increase Current
3) Excess Filler Wire 3) Reduce Filler Metal
Overlap
Suck Back*
Cause Remedy
Suck Back
Under flush
Cause Remedy
1) Inadequate weld beads in 1) Weld some more beads
final layer in final layer
2) Inadequate understanding on 2) Train / Qualify welder
weld reinforcement
3) Wrong selection of filler wire 3) Train / Qualify Welder
size
Under flush
Burn through*
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Root opening 2) Reduce root opening
3) Inadequate Root face 3) Increase root face
4) Improper weaving 4) Train / Qualify Welder
Tungsten Inclusion
Stray Arcing
Cause Remedy
1) HF Not In Operation 1) Rectify HF Unit
2) Inadequate Skill of Welder 2) Train the Welder
Arc Strikes
Thanks
Pulsed GTAW - Automatic
Pulsed GTAW - Automatic