GAS TUNGSTEN ARC WELDING

TUNGSTEN INERT GAS

INTRODUCTION

The aircraft industry developed the GTAW process for welding

magnesium during the late 1930s and the early 1940s. During that time,
helium was the primary shielding gas used, along with DCEP welding
current. These caused many problems that limited application of the GTA
welding process. But improvements in gas composition and a better
understanding of the importance of polarity improved the process’s
effectiveness and reduced its cost.

Before development of GTAW process, welding aluminum and magnesium

was difficult. The welds produced were porous and corrosion-prone.

Until the late 1940s, GTAW was the only acceptable process for welding
such reactive materials as aluminum, magnesium, titanium and some
grades of stainless steel regardless of thickness.
INTRODUCTION

GTAW uses an electric arc between a non-consumable tungsten

electrode and the work. Shielding is obtained from an inert gas or inert
gas mixture. Filler metal can be added as needed. The torch is usually
water cooled, but can be air cooled for low-current applications.

This type of welding can be accomplished by manual, mechanized, or

automatic methods. When filler metal is added, the process calls for a
two-handed technique,
technique as in oxyacetylene welding. Cold-wire and
hot-wire feeds are automated versions of that technique.

Slow heating and low temperatures combined with the slow

cooling rates that are characteristic of GTAW result in improved weld
metal and heat-affected zone (HAZ) mechanical properties. The tungsten
electrode provides the means of initiating the arc. The melting is
essentially slow and that most of the gases evolved can escape from the
weld pool before it freezes.
INTRODUCTION

For mechanized applications, filler wire may be added manually or by

the use of a wire feeder.

The classification for filler wire for GTAW operations is the same as that
for the GMAW process.
NON-CONSUMMABLE TUNGSTEN ELECTRODE

Tungsten,
Tungsten atomic symbol W, has the following properties:
• High tensile strength, 3,447 kg/mm2
• Hardness, Rockwell C 45
• High melting temperature, 3,410oC
• High boiling temperature, 5,630oC
• Good electrical conductor

Tungsten is produced mainly by reduction of its trioxide with hydrogen.

Powdered tungsten is then purified to 99.95+%, compressed, and sintered
(heated to a temperature below melting where grain growth can occur) to
make an ingot. The ingot is heated to increase ductility and then is swaged
and drawn through dies to produce electrodes.

These electrodes are available in sizes varying from 0.25 mm to 6 mm in

diameter. The tungsten electrode, after drawing, has a heavy black oxide
that is later chemically cleaned or ground off.
NON-CONSUMMABLE TUNGSTEN ELECTRODE

The high melting temperature and good electrical conductivity make

tungsten the best choice for a non-consumable electrode. The arc
temperature, around 6,000oC, is much higher than the melting temperature
of tungsten but not much higher than its boiling temperature of 5,900oC.

The thermal conductivity of tungsten and the heat input are prime factors in
the use of tungsten as an electrode.
NON-CONSUMMABLE TUNGSTEN ELECTRODE

Tungsten is a good conductor of heat. This conductive property is what

allows the tungsten electrode to withstand the arc temperature well above
its melting temperature.

The heat of the arc is conducted away from the electrode's end so fast that
it does not reach its melting temperature.

For example, a wooden match burns at approximately 1,647 oC. Because

aluminum melts at 971oC, a match should easily melt an aluminum wire.
However, a match will not even melt a 2-mm aluminum wire. The
aluminum, like a tungsten electrode, conducts the heat away so quickly that
it will not melt.
NON-CONSUMMABLE TUNGSTEN ELECTRODE
GTAW TORCH COOLING SYSTEM
GTAW TORCH COOLING SYSTEM
GTAW TORCH COOLING SYSTEM
ELECTRODE TIP SHAPE

The current-carrying capacity at DCEN is about ten times greater than that
at DCEP.

The preferred electrode tip shape impacts the temperature and erosion of
the tungsten.

With DCEN, a pointed tip concentrates the arc as much as possible and
improves arc starting with either a short, high-voltage electrical discharge
or a touch start.

Because DCEN does not put much heat on the tip, it is relatively cool,
the point is stable, and it can survive extensive use without damage, Figure
14-4A.
ELECTRODE TIP SHAPE
ELECTRODE TIP SHAPE

With alternating current (AC), the tip is subjected to more heat than with
DCEN. To allow a larger mass at the tip to withstand the higher heat the
tip is rounded. The melted end must be small to ensure the best arc
stability, Figure 144B.

DCEP has the highest heat input to the electrode tip. For this reason
a slight ball of molten tungsten is suspended at the end of a
tapered electrode tip. The larger mass of the tungsten above the molten
ball holds it in place like a drop of water on your fingertip, Figure 144C.
TYPES OF WELDING CURRENTS
TYPES OF WELDING CURRENTS
TYPES OF WELDING CURRENTS
CLEANING ACTION
TUNGSTEN CONTAMINATION
TUNGSTEN CONTAMINATION
SHIELDING GAS

The shielding gases used for the GTA welding process are argon (Ar),
helium (He), hydrogen (H), nitrogen (N), or a mixture of two or
more of these gases.

The purpose of the shielding gas is to protect the molten weld pool and the
tungsten electrode from the harmful effects of air.

The shielding gas also affects the amount of heat produced by the arc and
the resulting weld bead appearance.

Argon and helium are noble inert gases. This means that they will not
combine chemically with any other material.

Argon and helium may be found in mixtures but never as compounds.

Because they are inert, they will not affect the molten weld pool in any
way.
SHIELDING GAS
BACKING GAS
Root contamination caused by the surrounding atmosphere is not a major
problem when welding on mild steel pipe.

Some type of protection, however, is needed when welding on low-alloy

steel, stainless steel, aluminum, copper, and most other types of pipe.

The easiest method of protecting the root from atmospheric contamination

is to use a backing gas. The gas is used to purge the root area from the air.

The type of gas used for backing will depend upon the type of pipe being
welded.

Argon and helium are satisfactory for the backup purge when welding all
materials.

Nitrogen may be used satisfactorily for backing up welds in austenitic

stainless steel, copper, and copper alloys.

CO2 are often acceptable, depending upon the code or intended use of the
pipe system.
BACKING GAS
BACKING GAS
BACKING GAS
BACKING GAS

When a backing gas is used, the gas must have enough time to purge the
pipe completely. The joint is taped over to prevent the gas from being
blown out too fast. This will allow a slower flow rate to be used on the
purging gas. The tape is removed just ahead of the weld, Figure 16-13.
FILLER METALS SPECIFICATION
FILLER METALS SPECIFICATION
ADVANTAGES

• The GTAW process is capable of welding virtually all metals, even

extremely thin materials.

• The principal advantage of GTAW is that high-quality welds with

excellent visual appearance can be produced.

• Because no flux is used, the process is quite clean and there is no

slag to remove after welding.

• Little/no spatter.

• Arc and weld pool are clearly visible to the welder.

• All positions.

• Cleaning action with DCEP and AC.

DISADVANTAGES

• The skill level necessary to produce high-quality welds is acquired only

after much experience in manipulating the electrode and feeding the filler
wire.

• Because the process has a low tolerance for contamination, the base and
filler metals must be extremely clean prior to welding.

• GTAW is among the slowest of the available welding processes.

• Low productivity.

• Higher initial cost.