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GAS TUNGSTEN ARC WELDING

GAS TUNGSTEN ARC welding (GTAW) uses a nonconsumable tungsten electrode which must be shielded with an inert gas. The arc is initiated between the tip of the electrode and work to melt the metal being welded, as well as the filler metal, when used. A gas shield protects the electrode and the molten weld pool, and provides the required arc characteristics. This process is illustrated in Figure 1.6 below.

Figure 1.6
The process may employ direct current with positive or negative electrode or alternating current. In general, ac is preferred for welding aluminum and magnesium. Direct current electrode negative is preferred for welding most other materials and for automatic welding of thick aluminum. Thin magnesium sometimes is welded with direct current electrode positive. When ac is used with argon shielding, an arc cleaning action is produced at the joint surfaces on aluminum and magnesium. This cleaning action removes oxides and is particularly beneficial in reducing weld porosity when welding aluminum. When using dc, helium may be used as the shielding gas to produce deeper penetration. However, stringent precleaning of aluminum and magnesium parts is required with helium shielding. Argon and helium mixtures for gas shielding can provide some of the benefits of both gases. Regardless of polarity, a constant current (essentially vertical volt-ampere characteristic) welding power source is required. In addition, a high-frequency oscillator is generally incorporated in power sources designed for GTAW. High-frequency can be employed with dc to initiate the arc instead of touch starting to minimize tungsten electrode contamination. Normally, the high frequency is turned off automatically after arc ignition. The high frequency power is normally operated continuously with ac to maintain ionization of the arc path as the arc voltage passes through zero. Some special power sources provide pulsating direct current with variable frequency. This provision permits better control of the molten weld pool when welding thin sections, as well as when welding in positions other than flat. Several types of tungsten electrodes are used with this process. Thoriated and zirconiated electrodes have better electron emission characteristics than pure tungsten, making them more suitable for dc operations. The electrode is normally ground to a point or truncated cone configuration to minimize arc wander. Pure tungsten has poorer electron emission characteristics but provides better current balance with ac welding. This is advantageous when welding aluminum and magnesium.

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The equipment needed consists of a welding torch, a welding power source, a source of inert gas with suitable pressure regulators and flowmeters, a welding face shield, and protective clothing. Electric power requirements depend upon the type of material and the thicknesses to be welded. Power requirements range from 8 kw for a 200 A unit to 30 kw for a 500 A unit. Portable engine- driven power sources are also available. A small 200 A welding equipment setup will cost about $1000, while a simple automatic unit of 500 A capacity may cost about $5000. The addition of arc voltage control, slope control, and other accessories will materially increase the cost. Gas tungsten arc welding requires more training time, manual dexterity, and welder coordination than does SMAW or GMAW. The equipment is portable, and is applicable to most metals in a wide range of thickness and in all welding positions. Sound arc welds can be produced with the GTAW process when proper procedures are used. The process can be used to weld all types of joint geometries and overlays in plate, sheet, pipe, tubing, and other sturctural shapes. It is particularly appropriate for welding sections less than 3/8-in. (10mm) thick and also 1-to 6-in. (25.4-to 152.4-mm) diameter pipe. Thicker sections can be welded but economics generally indicate the choice of a consumable electrode process. This combination of GTAW for root pass welding with either SMAW or GMAW is particularly advantageous for welding pipe. The gas tungsten arc provides a smooth, uniform root pass while the fill and cap passes are made with a more economical process. Gas tungsten arc welding is generally more expensive than SMAW due to the cost of the inert gas, and is only 10 to 20 percent as fast as GMAW. However, GTAW will provide the highest quality root pass, while accommodating a wider range of thicknesses, positions, and geometries than either SMAW or GMAW. BACK TO FRONT PAGE

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