1.

0 DICTIONARY
SKILLS
At the end of the lesson, students
should be able to:
Acquire, understand and increase
specific vocabulary to facilitate
better understanding
 PRINCIPLES OF GAS TUNGSTEN ARC WELDING
(GTAW)

Process Description consumable

Gas Tungsten Arc Welding (GTAW), also known as tungsten inert gas (TIG) welding is a
process that produces an electric arc maintained between a non-consumable tungsten
electrode and the part to be welded. The heat-affected zone, the molten metal, and the
tungsten electrode are all shielded from atmospheric contamination by a blanket of inert gas
fed through the GTAW torch. Inert gas (usually Argon) is inactive or deficient in active
chemical properties. The shielding gas serves to blanket the weld and exclude the active
properties in the surrounding air. Inert gases, such as Argon and Helium, do not chemically
react or combine with other gases. They pose no odor and are transparent, permitting the
welder maximum visibility of the arc. In some instances Hydrogen gas may be added to
enhance travel speeds.
The GTAW process can produce temperatures of up to 35,000 F (19,426 C). The torch
contributes heat only to the workpiece. If filler metal is required to make the weld, it may be
added manually in the same manner as it is added in the oxyacetylene welding process, or in
other situations may be added using a cold wire feeder.
GTAW is used to weld steel, stainless steel, nickel alloys such as Monel and Inconel ,
titanium, aluminum, magnesium, copper, brass, bronze, and even gold. GTAW can also weld
dissimilar metals to one another such as copper to brass and stainless steel to mild steel.
Advantages of GTAW welding:
Concentrated Arc - Permits pinpoint control of heat input to the work piece resulting in a
narrow heat-affected zone.
No Slag - No requirement for flux with this process; therefore no slag to obscure the
welders vision of the molten weld pool.
No Sparks or Spatter - No transfer of metal across the arc. No molten globules of spatter
to contend with and no sparks produced if material being welded is free of contaminants.
Little Smoke or Fumes - Compared to other arc-welding processes like stick or flux cored
welding, few fumes are produced. However, the base metals being welded may contain
coatings or elements such as lead, zinc, copper, and nickel that may produce hazardous
fumes. Keep your head and helmet out of any fumes rising off the workpiece. Be sure that
proper ventilation is supplied, especially in a confined space.
Welds more metals and metal alloys than any other arc welding process.
Good for welding thin material.
Good for welding dissimilar metals together.
Disadvantages of GTAW welding:
Slower travel speeds than other processes.
Lower filler metal deposition rates.
Hand-eye coordination is a required skill.
Brighter UV rays than other processes.
Equipment costs can be higher than with other processes.
Concentrations of shielding gas may build up and displace oxygen when welding in
confined areas ventilate the area and/or use local forced ventilation at the arc to remove
welding fumes and gases. If ventilation is poor, wear an approved air-supplied respirator.

Exercise 1
Match the words in column A with the words synonym in meaning in Column B.

Column A Column B

non- flunctuation
consumable

shielded dangerous

react different

protected
transparent

preserved
dissimilar

respond
flux

see-through
hazardous
Exercise 2: Find the meaning of the words listed below using a dictionary.

1. Permits to allow something/ somebody

2. Spark to cause something/a very small bright piece of burning material
3. Spatter to cover somebody/something with small drops of something wet
4. Molten made liquid by very great heat
5. Fumes smoke/gases that smell unpleasant that can be dangerous
6. Ventilation to allow air to move freely in/out of a room or building
7. Lower to make/let something go down
8. Displace to remove and take the place of something
9. Remove to take somebody/something off or away
10. Respirator a tool of breathing
11. Concentrationa large amount of people/thing in one place
12. Alloy a metal made by combining two or more metallic elements, especially
to give greater strength or resistance to corrosion
13. Coating a thin layer of something that covers something else
14. Filler something that is full
15. Deposition a substance that has been left on a surface as the result of
natural/chemical process
16. Globules a small drop/ball of a liquid
17. Contaminants harmful/dirty things affected due to addition of other substances
18. Confined very small
19. Inert not able to move/act
20. Inactive doing nothing/not active

Exercise 3: Base on (Exercise 2), choose five words and create sentences using the
words chosen.

[Accept any suitable answers]

1. ______________________________________________________________

______________________________________________________________

2. ______________________________________________________________

______________________________________________________________

3. ______________________________________________________________
 ______________________________________________________________

4. ______________________________________________________________

______________________________________________________________

5. ______________________________________________________________
______________________________________________________________

3.0 READING SKILLS

At the end of the lesson, students
should be able to:

Use reading skills to comprehend

and perform tasks
Read the article below and answer the questions that follow.

The Welding - A Personal Perspective

1 Many people have no idea what welding is about and think of a welder as a dirty old
guy with a cigarette hanging out of his mouth, in a blue collar trade who either fixes stuff, or
works in a factory. Although there are many welders making great money and bennies in
factories (yes, many with cigs hanging out of their mouths) there are all kinds of other jobs
and processes. Welders, both male and female are working everywhere in the world from
high up on multi-story office towers to deep underwater in the oceans. They are nuclear code
welders, plastic welders, explosive welders, welders who work on LIVE armed missiles,
space station component welders, robotic welders and thats just a few right off the top of my
head!

10 Welding is a much diversified trade involved in at least half of our Gross National
Product and a huge part of our everyday lives. Think about it, we use products or work or live
in structures that are welded just about every day of our lives. Pipes bring us gas and water,
we travel over roads with bridges that are welded, ride in cars/trucks/busses that have been
welded, and our crumbling infrastructure is going to require probably the most welding in
history!

16 When I was a kid about seven years old we were at an intersection and I heard my
mom and dad talking about how daring some guys were. My dad was a World II and Korean
War combat Vet and even at my young age I knew if he called someone daring they were the
real deal. I looked up and saw Iron Workers WAY up on a high-rise with sparks dropping
down like and orange waterfall. I didnt have a clue what the sparks were, nor did I realize I
had just seen my first welders in action.

22 A couple of years later it happened again but this time it was my mom and her friend
gasping as they saw some Iron Workers welding on the Rio Grande Gorge bridge. There were
those crazy-brave guys and again the sparks were falling. I still didnt really know why, but it
intrigued me enough that I mentioned it in one of the first articles I ever wrote. It didnt make
me decide on a career in welding, but it did catch my interest. Little did I know that Id end
up making a career starting in an oilfield/agriculture equipment repair shop, become lead
welder at a black iron plant, become a member of the International Association of Bridge,
Structural, Ornamental and Reinforcing Iron Workers, and then teach Structural Welding for
twenty years!

31 I started out at a Vocational College that was run by my great mentors, Phil Newell
and Mike Waldrop. Google Phil Newell Mike Waldrop welding and you can check out
what Ive said about them in prior articles. They were my foundation and Ill always
remember them fondly. It was old school welding back then and we started out
Oxy/Acetylene welding and had to pass 2G, 3G and 4G plate tests. It separated the men from
the boys and caused a lot of people to change their minds about getting into the welding
trade.

37 Actually, there are four main processes in welding; Stick (Shielded Metal Arc
Welding or SMAW), Mig (Gas Metal Arc Welding or GMAW), Tig (GTAW discussed
above) and Flux Core (Flux Cored Arc Welding or FCAW.)

40 I give my high school students a funny way of remembering the latest acronyms. Ill
look at one of them and tell the class that he or she will ask for SMAW potatoes at the dinner
table. Another will ask his/her dad if he will buy them a 12 string GTAW. Another cant wait
for their Grandpa and GMAW to come visit. (I learned the hard way to make sure the
students grandmother is still alive before using this one!).And I will tell them that FCAW is
a rude way of telling someone, well, Ill stop right there on that one!

Taken from: http://www.keenovens.com/articles/welding-processes.html

1. What is the article about?

The article is about the thoughts on welding; things around the author that
relates him to it, how it can be part of the authors life as well as the main
processes on welding.

2. In paragraph 1, what does blue collar trade mean?

a trade that performs manual labor in US usage. Blue-collar work may involve
skilled /unskilled manufacturing, mining, sanitation, custodian work, oil
field, construction, mechanical, maintenance, technical installation and many
other types of physical work. Often something is physically being built or
maintained.

3. What do people always think upon the welders?

Welders make great money

4. Why they think so?

It is because everything in our daily lives engages with welding processes; from
the pipes to the bridges of roads that we use every day.

5. State the welding structures found in our daily lives.

 a) Pipes
b) Bridges
c) Cars

6. What is the authors first experience on welding?

His first experience was at the age of seven, when he saw Iron Workers WAY up
on a high-rise with sparks dropping down like an orange waterfall.

7. In your opinion, why does the author become interested in welding?

Accept any suitable answers.

8. Name the four main processes of welding.

a) Stick (Shielded Metal Arc Welding or SMAW),
b) Mig (Gas Metal Arc Welding or GMAW),
c) Tig (GTAW)
d) Flux Core (Flux Cored Arc Welding or FCAW.)

9. The author used acronyms in order to remember the four main processes easier. In
your own idea, suggest another way of remembering the processes easily.
Accept any suitable answers.

10. What type of welder do you want to be in the future and why?
Accept any suitable answers.

Exercise 2: Based on the reading, elicit 10 words and come out with new sentence for
each.

Accept any suitable answers.

1._________________________________________________________________________
___________________________________________________________________________

2._________________________________________________________________________
___________________________________________________________________________

3._________________________________________________________________________
___________________________________________________________________________

4._________________________________________________________________________
___________________________________________________________________________
5._________________________________________________________________________
___________________________________________________________________________

6._________________________________________________________________________
___________________________________________________________________________

7._________________________________________________________________________
___________________________________________________________________________

8._________________________________________________________________________
___________________________________________________________________________

9._________________________________________________________________________
___________________________________________________________________________

10.________________________________________________________________________
___________________________________________________________________________

Based on the article, write a summary on:

What are welding stuffs engage in the authors life

How welding can be his career

Your summary must:

Be in continuous writing
Be written in one paragraph
Use material from line 10 to line 36
Not be longer than 80 words, including the 10 words given below.

Begin your summary with:

There are many things around us involving welding. First, the [5 marks]

1) products or work or live in structures that are welded just about every day of our
lives.
2) Pipes bring us gas and water/
3) we travel over roads with bridges that are welded/
4) ride in cars/trucks/busses that have been welded,
5) the crumbling infrastructure
6) at the age of seven, when he saw Iron Workers WAY up on a high-rise with
sparks dropping down like an orange waterfall.
7) Couple years later, he saw some Iron Workers welding on the Rio Grande Gorge
bridge, his interest was built.
8) end up making a career starting in an oilfield/agriculture equipment repair shop,
become lead welder at a black iron plant
9) become a member of the International Association of Bridge, Structural,
Ornamental and Reinforcing Iron Workers
10) teach Structural Welding for twenty years
11) he started out at a Vocational College that was run by great mentors, Phil Newell
and Mike Waldrop