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12 September 2014 ProQuest
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1. GTAW Welding: Touching on the basics...................................................................................................... 1
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GTAW Welding: Touching on the basics
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Abstrak (Abstract): Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding is used
in many aircraft applications. GTAW provides a clean, strong weld joint that makes it ideal for assembling and
repairing various aircraft components. In this article, we will discuss the basic theory of GTAW and cover some
basic welding and setup tips.
Teks lengkap:
Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding is used in many aircraft
applications. GTAW provides a clean, strong weld joint that makes it ideal for assembling and repairing various
aircraft components. In this article, we will discuss the basic theory of GTAW and cover some basic welding and
setup tips.
Basic theory
In gas tungsten arc welding, a non-consumable tungsten electrode is used to establish an arc on the base
metal. The heat of the arc melts the base metal and produces a weld pool. In contrast to normal arc welding, in
GTAW an inert gas shields the weld area in order to prevent air from contaminating the weld. This shielding gas
prevents oxidation of the tungsten electrode, the molten weld puddle, and the heat-affected zone adjacent to the
weld bead.
In a typical GTAW setup, an AC/DC welding machine is used with a flow of shielding gas. The shielding gas
goes through a regulator and flow meter and on to the torch. The torch has a collet/collet body combination that
holds the electrode. A heatresistant cup or ceramic nozzle surrounds the electrode and controls the gas shield.
Personal protective equipment
Although GTAW does not produce the metal spatter that is common with arc or stick welding, it still generates
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intense heat and light. In fact, the clearer atmosphere around the GTAW arc can cause up to twice the amount
of infrared and UV rays comparetrto formal arc welding. Any expC&ed skin will be damaged similar to an
extreme sunburn. Welders must wear a welding helmet. Welder's protective gloves and clothing should also be
used. Fire-resistant cloth and leather clothing and accessories are recommended. Cotton should not be used as
it doesn't provide sufficient protection and it deteriorates quickly under the infrared and UV rays produced by the
welding process. In addition, dark clothing should he used to reduee reflection of light behind the helmet.
Other safety precautions
The following general precautions should be observed to protect you and co-workers from (he hazards
associated with GTAW:
Ensure electrical connection leads are in good condition and tight prior to use. They should be protected to
prevent accidental damage from hangar traffic.
Make sure you have adequate ventilation. Since GTAW uses inert gases during the process, if it is used in an
enclosed area it can displace breathing air and can he hazardous without proper ventilation. In addition, ozone
is produced during the welding process. The amount of ozone produced varies with type of electrode used,
amperage, and argon flow. In poorly ventilated areas, ozone levels can increase to harmful levels. Whenever
possible, draw fumes and contaminated air away when welding.
Flammable materials should not be carried in clothing pockets.
Shielding curtains should be placed around all jobs so that workers in adjacent areas are not exposed to the
welding arcs.
Shielding
In GTAW, the gas used to shield the welding arc and hot metals is an inert gas. Inert gases are gases whose
atomic structures do not allow them to react with metals or other gases. Argon, helium, or an argon-helium
mixture is used as the inert gas in GTAW.
Argon is a relatively heavy gas. It has several benefits when used in GTAW. It requires a lower arc voltage than
other shielding gases for a given arc length and current used (ideal for thin metal welding). It also provides
easier arc starting. Its heavier weight as compared to helium provides for good shielding with lower flow rates.
In contrast to argon, helium is the lightest of the inert gases. Because of its light weight, about two to three times
more helium is needed as compared to argon to shield the weld area. Despite this, helium has an advantage
over argon in that it can be used with greater arc voltages. Because of this, helium is preferred when working
with thick metal sections.
Another difference in the two gases is their cleaning ability. Both helium and argon allow for good cleaning
action when using DC, However, when using AC, argon provides for better cleaning action. Argon also provides
better arc stability than helium when using AC.
Proper gas selection
You want to make sure to use the right gas with GTAW. Usually, pure argon is used, although thicker welding
may require an argon/helium or other specialty mix. If you use the wrong gas mixture, such as a 75 percent
argon/25 percent CO2 that is common for GMAW, the tungsten electrode will quickly be consumed or deposited
in the weld puddle.
Gas flow rate
Setting a proper gas flow rate is another important element to successful GTAW. Contrary to what may seem to
be common sense, more isn't better. If you are welding in a flat position, a flow rate of about 15 to 20 cubic feet
per hour (CFH) is typically adequate. For overhead welding, you can start at about 20 CFH and increase the
flow by small adjustments of about 5 CFH if necessary.
So why is too high a flow rate a bad thing? Well, if the gas flows out of the torch at too high a velocity, it ends up
bouncing off the surface being welded and starts a swirling motion parallel to the torch cup called a venturi. This
venturi effect will suck air into the gas flow, creating an impure weld atmosphere. This results in pinholes in the
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weld.
Accessories
The GTAW torch can either be air cooled or water cooled. If most of the welding you do is at 200 amps or less,
an air-cooled torch is adequate. If welding above 200 amps, a water-cooled torch should be considered.
Controls are also offered in either foot pedal control or torch control. Foot pedal control tends to be more
popular where work is done in an area that affords mobility. A fingertip control can be beneficial when working in
an awkward position or where less mobility is available.
Electrodes
Many different electrode types are available including thoriated, lanthaniated, ceriated, and pure tungsten.
When choosing an electrode, follow manufacturers' recommendations and choose the one that is best for you.
Some characteristics to consider in an electrode are good ignition and re-ignition properties, constant arc, long
lifetime, and high currentloading capacity.
As a safety note, 2 percent (thoriated) tungsten contains thoria, a radioactive element. When grinding on these
electrodes, it is advisable to use some sort of collection device in the form of a vacuum or a liquid hath so that
the grinding dust does not become airborne.
Good welding practices
You want to get in as comfortable a position as possible. Brace your arm to allow for steady torch movement.
Many GTAW welders hold the torch like a pencil to afford the best control.
You want to hold the torch at the proper angle. If the torch is perpendicular to the work piece, it will be difficult to
view the welding process, The angle of the torch relative to perpendicular should be about 15 to 20 degrees. If
this angle is exceeded too much, it can lead to less penetration, poor shielding gas coverage, and general arc
instability.
In regards to travel direction, the torch should be pushed away from (ahead of) the weld puddle. This ensures
proper gas coverage of the weld puddle and offers the welder a good view of the weld puddle.
Get comfortable with your welding equipment. Practice welding on scrap metal. This is a good way to become
familiar with the welding equipment, allowing for more confidence when doing the actual welding.
This article touched on some basics associated with GTAW. For more information, or to inquire about training
opportunities available, contact the equipment manufacturer.
Additional Resources
Lincoln Electric
(216) 481-8100
www.lincolnelectric.com
Miller Welding
(920) 734-9821
www.millerwelds.com
Subjek: Welding; Aircraft; Safety management; Guidelines; Gases;
Lokasi: United States--US
Klasifikasi: 9190: United States; 5340: Safety management; 9150: Guidelines
Judul: GTAW Welding: Touching on the basics
Pengarang: Escobar, Joe
Judul publikasi: Aircraft Maintenance Technology
Volume: 16
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Edisi: 8
Halaman: 18-20
Jumlah halaman: 3
Tahun publikasi: 2005
Tanggal publikasi: Jul 2005
Tahun: 2005
Bagian: Airframe Technology
Penerbit: Cygnus Business Media, Inc
Tempat publikasi: Ft. Atkinson
Negara publikasi: United States
Subjek publikasi: Transportation--Air Transport
ISSN: 10723145
Jenis sumber: Magazines
Bahasa publikasi: English
Jenis dokumen: Cover Story
Fitur dokumen: Photographs
ID dokumen ProQuest: 223764189
URL Dokumen: http://search.proquest.com/docview/223764189?accountid=31324
Hak cipta: Copyright Cygnus Business Media Jul 2005
Terakhir diperbarui: 2012-09-27
Basis data: ProQuest Career and Technical Education
ProQuest Research Library
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