Table 19-7 Titanium Weldability Rating

Alloy Alloy Designators Rating1 Filler Metal

Commercially pure (CP) Ti-0.15 O2 A ERTi-1
Ti-0.20 O2 A ERTi-2
Ti-0.35 O2 A ERTi-4
Alpha alloys Ti-0.2 Pd A ERTi-7
Ti-5 Al-2.5 Sn B ERTi-6
Ti-5 Al-2.5 Sn ELI 2
A ERTi-6ELI
Alpha-beta alloys Ti-6 Al-4V ELI A ERTi-5ELI
Ti-7 Al-4Mo C ERTi-12
Ti-8 Mn D Welding not recommended
A: Excellent; useful as welded, near 90% joint efficiency if base metal annealed condition. B: Fair to good; useful as welded, near 100% joint efficiency if base metal annealed condi-
1

tion. C: Limited to special applications; cracking can occur under high restraint. D: Welding not recommended; cracking under moderate restraint; use preheat (300350F) followed
by postweld heat treatment.
 LI: Extralow interstitial impurities are specified. These interstitial impurities are carbon, hydrogen, oxygen, and nitrogen, and both the filler metal and base metal are low in these
E
2

impurities.

metal should closely match the alloy content of the base

metal being welded.
Shielding of the titanium weld and surrounding metal
(including the hot end of the filler rod) that reach tem-
peratures of 500F is required. When doing manual
open air welding (not in a bubble or totally enclosed
chamber), care must be taken to prevent atmospheric
contamination of the titanium. Since titanium has a very
low thermal conductivity, it stays hot for a long time
after the welding arc has moved along the joint. Thus, a
trailing gas is essential. This can be accomplished with Fig. 19-5 Torch trailing shield for TIG welding of titanium and
a large gas lens on the torch or a trailing gas shoe that other reactive metals. Huntingdon Fusion Techniques
attaches to the TIG torch. This metal shoe (chamber)
has a porous metal diffuser to allow the gas to blan-
ket the titanium until it has cooled below its oxidation
shield. The primary gas shielding is what is flowing
temperature. Figure 19-5 is an example of a trailing gas
through the torch, and the secondary gas shielding is
what is flowing through the trailing shield. If the back
side of the joint is going to be exposed to oxidation tem-
peratures over 500F, it must also be protected from the
atmosphere by a backing gas shielding or, in the case
of pipe or tubing, purging the inside of the pipe or tube.
ABOUT W E L DIN G Figures 19-6, 19-7, and 19-8, page 602 show the color
indications that denote the amount of acceptable oxidi-
Resistance Weld zation when welding titanium.
Which would you rather try to resistance
weld: copper, aluminum, or stainless steel? Copper
and aluminum are metals that do not resist electricity
Copper and Its Alloys Copper is one of the oldest met-
well, which makes them difficult to resistance weld. But als used. It is not a scarce metal and is readily mined.
stainless steel is a good resistor and resistance welds It has a melting point of 1,981F. Copper lends itself to
easily. all of the modern methods of fabrication. The weldabil-
ity of each copper alloy group depends largely upon the

Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate) Chapter 19 601
Fig. 19-6 A glossy silver appearance indicates an accept-
able weld. Navy Joining Center. Images are for representational
purposes only and should not be used for weld color inspection
because of possible color distortion in the print reproduction
process.
Fig. 19-8 A gray appearance with multicolor titanium oxides indicates
a rejectable weld. Navy Joining Center. Images are for representational
purposes only and should not be used for weld color inspection because of pos-
sible color distortion in the print reproduction process.
alloying elements. Copper is used widely in all industries
and has a special application in the fabrication of electri-
cal equipment.
Copper is one of the best conductors of electricity and
heat. It is highly resistant to corrosion. When mixed with
certain other elements, copper is both ductile and wear
resistant, and it can be heat treated.
Copper has the following disadvantages for welding:
It is brittle at high temperatures and presents problems
in jigging.
It is strongest when cold worked. The high welding
temperatures cause it to losestrength.
602 Chapter 19 Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate)
Fig. 19-7 A gray appearance with multicolor titanium oxides
indicates a rejectable weld. Navy Joining Center. Images are for
representational purposes only and should not be used for weld color
inspection because of possible color distortion in the print reproduction
process.
Stress reversals cause the metal to be
come hard and brittle so that it breaks from
fatigue.
While pure copper presents no great difficulty
in welding, many of its alloys require special
treatment. The following copper alloys lend them-
selves to welding:
Copper-silicon alloys such as Everdur and
Herculoy
The copper-aluminum alloys known as alu-
minum bronze
The copper-phosphorus alloys known as
phosphor bronze
Copper-nickel alloys
Those copper alloys containing zinc, tin, or lead are ei-
ther difficult or impossible to weld. These materials have
a low melting point that causes them to volatize under the
intense heat of the arc. They can be successfully brazed,
however, with the oxyacetylene process.
DCEN is used for welding pure copper and most cop-
per alloys. Alternating current with stabilization is rec-
ommended, however, for beryllium copper, aluminum
bronze, and copper alloys less than 20 gauge thick. Cur-
rent settings should be higher for copper and its alloys
than for most other metals because of their high ther-
mal conductivity. Always provide good ventilation when
welding beryllium copper and when using certain fluxes.
Copper has a tendency to form oxides, which must be re-
moved just before welding.
Consult Table 19-8 for the proper operating conditions
for welding deoxidized copper with DCEN.
Nickel and Nickel-Base Alloys Nickel has wide applica-
tion in those industries in which corrosion and low and
high temperatures are encountered. It is very ductile and
can be worked readily. Its tensile strength, elasticity, melt-
ing point, and magnetic properties are similar to those of
steel. Following is a list of the important high nickel alloy
metals:
The nearly pure nickels and Duranickel, a high
strength, low alloy nickel
The Monels, which are about two-thirds nickel and
one-third copper
The Inconels, which are higher in nickel and iron
content than the Monels. They are outstanding in
their ability to resist damage from abrupt changes in
temperature.
The Nimonics, which contain approximately 80per-
cent nickel and 20 percent chromium. These alloys are
used in gas turbine engines.
The Hastelloys are alloys of nickel, molybdenum,
and iron. They have a high resistance to acids.
While nickel can be welded with the shielded metal arc
welding process, gas tungsten arc welding has the advan-
tage of eliminating slag entrapment in the weld. Gener-
ally, DCEN is recommended. On thin material, however,
alternating current with stabilization has the advantage of
lower heat input. The current values and electrode sizes
are similar to those used to weld carbon steel. Argon,
helium, and a mixture of these gases are recommended
for most applications, but argon is recommended for thin
materials.
Consult Table 19-9 for the proper operating conditions
for welding the Hastelloys with DCEN.

Table 19-8 Operating Conditions with DCEN and Argon Shielding Gas: Deoxidized Copper1

Work Preheat Tungsten Filler

Thickness Welding Current, Temp. Diameter Rod Size Cup Size Gas Flow
(in.) Flat Position (A) (F) (in.) (in.) (in.) (ft3/h)
1
16 110150 16
1 1
16 8
3
15
1
8 175250 3
32 3
32 8, 2
3 1
15
3
16 250325 500 1
8 1
8 2
1
15
1
4 300375 600 1
8 1
8 2
1
15
3
8 375450 800 3
16 3
16 2
1
17
1
2 500700 900 3
16 1
4 2, 58
1
17

Optimum conditions for each application should be determined by trial.

1

Source: Eutectic Corp.

Table 19-9 Operating Conditions with DCEN and Argon Shielding Gas: Hastelloy Alloys1

Work Tungsten Filler

Thickness Welding Current (A) Diameter Rod Size Gas Flow
(in.) Flat Vertical (in.) (in.) (ft3/h)
1
16 6090 5575 16
1 1
16, 332 20
1
8 100125 80110 32
3
32
3
25
3
16 130175 100140 32
3
32
3
30
1
4 130175 100140 32
3 1
8 35
3
8 140200 110160 32
3 1
8 40
1
2 200250 160250 1
8 32
5
40
1
Optimum conditions for each application should be determined by trial.
Source: Eutectic Corp.

Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate) Chapter 19 603
 Table 19-10 Welding Dissimilar Metals

Materials to Be Joined Type of Current Rod Type

Stainless steel to cast iron DCEN Oxweld 26
DCEN Nickel and stainless steel
Stainless to carbon or low alloy steel 310 stainless
Copper to stainless steel DCEN None required
Copper to Everdur Oxweld 26
Cupro-nickel to Everdur Oxweld 26
Nickel to steel DCEN Nickel
Hastelloy Alloy C to steel DCEN Hastelloy W; Inconel; Nickel; or
310 stainless
Aluminum to steel A.C. with stabilization No. 25M bronze rod; B.T. silver
brazing alloy; Oxweld 14 Al. Rod
Stainless steel to Inconel DCEN 310 stainless
Tungsten to molybdenum Platinum
Copper and Everdur to steel DCEN Copper or 26 Everdur

Welding Dissimilar Metals The requirements of the specific job

Many industrial fabrications make it necessary to join
dissimilar metals. Although both the oxyacetylene and
the shielded metal arc welding processes may be used, a
greater variety of materials can be joined with gas tung-
sten arc welding.
Consult Table 19-10 for the listing of dissimilar metals
that can be joined and the type of current and filler rod
to use. The filler rod should be selected with care. Table
19-10 lists one companys recommendations.
Hard-facing
Hard-facing is a process of applying a hard, wear-resistant
layer of metal to the surfaces or edges of parts. Hard-
facing rods are deposited for the purpose of improving re-
sistance to impact or abrasion, or both. This may be done
to build up worn areas to make them as good as new or to
put hard, wear-resistant cutting edges on soft, ductile ma-
terials. Hard-facing is used for stone-crushing equipment,
power shovel buckets, farm implements, and many other
applications. While both the oxyacetylene and the shielded
metal arc welding processes may be used, somewhat better
results can be obtained with the gas tungsten arc process.
Consult Table 19-11 for a listing of materials that may be
hard-faced and the proper operating conditions.
Filler Metals
The composition of filler metals for the various metals
welded by the gas tungsten arc welding process are se-
lected on the basis of the following criteria:
The type of metal being welded
Ease of welding
Characteristics desired, such as strength; ductility;
hardness; machinability; and resistance to corrosion,
impact, abrasion, and oxidation
Preheat and postheat requirements
Color matching, when this is important
Type of shielding gas being used
You are urged to become familiar with the AWS speci-
fications for filler metals. On most welding jobs the type
of filler metal will be specified by the engineering depart-
ment. It is necessary, however, for the welder to know the
types of filler metals and their uses.
Joint Design and Practices
There is no limit to the types of joints that may be welded
with the gas tungsten arc welding process. The basic types
of joints used for plate welding are butt, lap, edge, corner,
and T-joints. They are similar to those used with other
welding processes. Selection of the proper design for a
particular application depends primarily on the following
factors:
Physical properties desired in the weld
Cost of preparing the joint and making the weld
Type of metal being welded
Size, shape, and appearance of the assembly to be
welded.

604 Chapter 19 Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate)
 Table 19-11Hard-facing

Deposit
Argon Rockwell
Surfacing Current Welding Flow (Rc)
Base Metal Material Type Amperes Rod Type Technique (ft3/h) Hardness Remarks
Mild & Haynes a.c.1
Stellite #1 Backhand 25 54
stainless Stellite a.c.1
Stellite #6 Backhand 25 39
steels alloys a.c.1 Stellite #12 Backhand 25 47
a.c.1
Stellite #93 Backhand 25 62
a.c.1
Hascrome Backhand 25 2343 Extruded rod has
better weld
characteristics
than rolled rod
Copper Stellite #6 alloy DCEN 180230 for Stellite #6 Forehand 15 42 Arc directed
3
16-in. mainly at
material welding rod
Steel, copper, Aluminum DCEN Aluminum Forehand 10 150300
& silicon bronze bronze rods
bronze
Mild steel & Bronze & a.c.1 or DCEN 150 for 12-in. Aluminum Forehand 10
cast iron copper material bronze &
copper rods
Stainless steel Silver a.c.1 160 for 12-in. Either 10 Plates pickled
material prior to
surfacing
Mild steel Stainless steel a.c.1 or DCEN Forehand 10
Mild steel Lead DCEN 75 Forehand 10 Steel ground or
pickled and
then coated
with liquid
soldering
flux before
surfacing
Carbon & alloy Tungsten DCEN 300375 Tube of 30
tool steels carbide 8
15mesh
tungsten
particles
A.C. (alternating current with stabilization) develops maximum hardness values; DCEN will permit higher welding speeds.
1
605
 Other considerations include the following:
Number and size of tacks
Purging and shielding gas
Root face, root opening, and bevel
Number of passes required Backup Bar
Size of filler rod
Fig. 19-9 Grooved backup bar for square and beveled-butt
Whether or not rod is required for the first pass and
joints.
whether or not a dressing pass is permitted
Method of striking and breaking the arc
Whether the direction of travel is moving vertically up
or down (aluminum should not be welded vertically
down; porosity will be worse)
Allowable protrusion and reinforcement
Type of electrode
Type of welding power Backup Bar
Tolerances of fitup and alignment
Fig. 19-10 Flat backup bar for upset butt joints.
Whereas gas tungsten arc welding is particularly
suited to the welding of materials up to 18 inch in thick-
ness, it may also be used to weld heavier thicknesses of
metals. The MIG/MAG process may be used on heavy
stock with better results. The nature and application of
the joint is a major consideration. Cost must also be con-
Extra plate positioned on underside of lap joint of
sidered in determining the welding process for a particu- equal thickness to that being welded.
lar job.
Usually, filler rod need not be used for thinner materi- Fig. 19-11 Backing for lap joints.
als. Careful consideration should be given to the welding
of heavy carbon steel since it is quite possible that the gas
metal arc or MAG process is more suitable. of the weld from atmospheric
No matter what type of joint is used, proper cleaning of contamination. Atmospheric
the work before welding is essential if welds of good ap- contamination causes weld
pearance and sound physical properties are to be obtained. porosity, poor surface ap-
This is of special importance in welding some alloys such pearance, cracking, and burn
as aluminum and magnesium. Welds in these metals will through.
be defective if even minute quantities of foreign material The weld may be backed
contaminate the inert gas atmosphere. up by (1) metal or ceramic
On small assemblies, manual cleaning with a stain- backup bars, (2) an inert gas
less-steel wire brush, stainless-steel wool, or a chemical Angle positioned on side
atmosphere on the weld un-
opposite to that being welded.
solvent is usually sufficient. Do not grind aluminum or derside, (3) a combination of
magnesium on an emery wheel. Be sure to remove com- Fig. 19-12 Backup for the first two methods, or
pletely all oxide, scale, oil, grease, dirt, and rust from the T-joints. (4) flux painted on the weld
work surfaces. underside.
Precautions should be taken when using certain chem- Metal backup bars should not actually touch the weld
ical solvents for cleaning purposes. The fumes from zone. (See Figs. 19-9 through 19-12 for typical backup for
some chlorinated solvents break down in the heat of the butt, lap, and T-joints.) The material used for making a
electric arc and form a toxic gas. Ventilating equipment backup bar is determined by the composition of the mate-
should be provided to remove fumes and vapor from the rial being welded. A copper bar may be used to back up
work area. welds in stainless steel. For the welding of aluminum or
magnesium, the bar should be made of stainless steel or
Weld Backup steel. Carbon steel can be used for carbon steel welding.
The joint should be backed up on many gas tungsten Very often, backup bars are water cooled to carry off the
arc welding applications. Backing protects the underside heat of the welding operation.

606 Chapter 19 Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate)
 When the final weld composition must conform to
extremely rigid specifications, extra care must be taken
to exclude all atmospheric contamination from the weld.
This is accomplished by introducing an atmosphere of
inert gas on the back side of the weld. Nitrogen may be
used for stainless steels. Argon should be used for other
metals that oxidize readily or react with nitrogen at high
temperatures. Review Chapter18 for a detailed presenta-
tion of shielding gases.
Setting Up the Equipment
Gas tungsten arc welding is a precision technique. Care
must be taken to make sure that the equipment is set up
in the proper way and that all of the variables are cor-
rect for the particular welding job to be performed. The
procedure for setting up the equipment before welding re-
quires checking every detail. You should make the checks
described in the following paragraphs before starting to
weld. Consult Chapter18 to review many of these points.
1. Make sure that you have a torch of the proper type
and size to meet the requirements of the welding
job.
2. Check the size, type, appearance, and position of the
tungsten electrode in the torch. It should have the di-
ameter recommended for the amount of current and
the electrode holder used. See Table 18-7, page 577,
and Table 19-12. The end of the electrode should be
clean and smooth. A contaminated electrode end in-
dicates that during a previous use the inert gas was
shut off before the electrode cooled, that there was a
gas leakage in the gas supply system or the torch, or
that the electrode tip was contaminated by touching
metal. If the tip is not too rough, it may be cleaned
with a fine emery cloth. When welding aluminum,
use a rounded tip with conventional a.c. sine wave
and a tapered tip for a.c. with square or enhanced
square wave power sources. When using DCEN
for steel, stainless steel, titanium, and so on use a
pointed tip.
Table 19-12 General Sizes of TIG Electrode Holders and Diameters
of the Electrodes That Fit Them
General Sizes of TIG
Electrode Holders
Small holder (100 A)
Medium holder (250 A)
Large or heavy-duty holder (500 A)
Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate) Chapter 19 607
3. Check the torch for the proper gas cup type and
size. Make sure that it is clean and free of spatter. If
it is important to see the weld clearly, you may wish
to use a glass cup.
4. Check all the connections on the gas supply for
leaks. If there is some reason to doubt a connection,
check it with the proper leak check solution.
5. Check all work connections. Pay special atten-
tion to the location of the work connection to the
work and the location of the work connection in
relation to the joint design and the direction of
welding.
6. Open the main shutoff valve of the cylinder of inert
gas and adjust the gas flow to meet the needs of the
particular job. See Chapter 18, pages 558559.
7. Before turning on the coolant supply, make sure that
the pressure is not higher than that recommended
by the torch manufacturer. Make sure that there are
no leaks in the coolant supply. The water should
be routed to cool the torch head first, and then the
power cable.
8. Adjust the current range for the joint being welded
and the size of the tungsten electrode. The position
of welding also makes a difference here. As with the
shielded metal arc process, vertical and overhead
welding generally requires a lower current setting
than other positions.
9. It is assumed that you have the proper eye and skin
protection for welding and that you will take the
necessary safety precautions.
SH OP TA L K
Torch Sleeve
A torch sleeve is a flexible material that
goes over the cables of water-cooled torches. These
lightweight sleeves keep the thermal plastic hoses from
contacting hot materials and melting.
Electrode Diameter (in.)
0.010, 0.020, 0.040, 116, & 332
0.020, 0.040, 116, 332, & 18
1
16, 332, 18, 532, 316, & 14
(Some special holders516, 38)
Safe Practices
In welding with the gas tungsten arc welding process, ob-
serve the same precautions and safe practices that would
apply to any other electric welding operation. In any form
of electric welding, there are potential shock hazards, burn
hazards, and fire hazards. In addition, welding operations
on certain metals and alloys may produce unpleasant or
dangerous fumes. For a detailed treatment of this subject,
you are urged to secure materials from such organizations
as the American Welding Society and various welding
equipment companies.
The welder should also be properly protected from the
rays of the arc. This requires suitable clothing to cover
all exposed skin surfaces and a welders helmet with the
proper shade of glass to protect the eyes and face. The
shade of the glass lens depends on the intensity of the arc.
Table 19-13 lists the recommended lens shade for different
current ranges.
Gas Tungsten Arc
Welding Safety Rules
Observe the following rules when welding with the TIG
process:
Always use a welding helmet equipped with a shaded
number lens suitable to the welding current you are
using. The helmet should be mounted on an adjustable
headband or, if there are overhead hazards, on a safety
hardhat.
Cover all skin surfaces with leather, heavy clothing, or
other adequate protection against burns from sparks,
the arc ray, and spatter. (See Fig. 19-13.)
Recommended personal protective equipment
includes the following:
Helmet
Safety glasses
Leather cape (or treated clothing)
Sleeves
Table 19-13 Correct Lenses for Various
Current Settings
Shade No. Welding Current (A)
6 Up to 30
8 3075
10 75200
12 200400
14 Above 400
608 Chapter 19 Gas Tungsten Arc Welding Practice: Jobs 19-J1J19 (Plate)
Apron
Ear plugs, if welding vertically or overhead
Gauntlet gloves
Heavy, flameproof shirt and pants (without cuffs)
Safety shoes
Do not weld in or near flammable gases, powders, or
liquids, or in or on untreated containers that have held
such materials.
Remove or protect all combustible material in
the welding area. If uncertain of the adequacy of
the protection, have a worker stand by with a fire
extinguisher. Make sure a fully charged, proper
type fire extinguisher is available. If you are uncer-
tain, dont weld until the safety issues have been
resolved.
If welding is being done in an area where welding is
not normally done, a hot work permit will be used.
These permits are used when hazards are involved in
cutting and welding operations.
The welding area should be dry and uncluttered to
avoid electric shock and falls.
Be sure you have adequate ventilation. Use spe-
cial precautions when toxic fumes, whether from
cleaning fluids, coatings, or the metal itself, are
given off.
Use nonreflective welding curtains to protect others
in the area. Even short exposure to tungsten arc rays
can burn the eyes, and skin burns from arc rays or
molten metal spatter must be prevented.
The TIG torch, power supply unit, service leads,
work connections, inert gas equipment, and protective
equipment should be inspected and in good condition
before welding.
Fig. 19-13 Student is properly protected and is in the proper
position for bench welding. Location: Northeast Wisconsin Technical
College McGraw-Hill Education/Mark A. Dierker, photographer