Gas Tungsten Arc Welding (GTAW)

1. Introduction
In this lab, you will examine the different GTAW welding techniques, GTAW of steel vs. aluminum
and the effects of arc length, the effects of different electrode tip angles on the weld width and the
stability of the welding arc.

2. Equipments and Materials

• Miller Dynasty 200 welding power supply.
• 3
/ 32 " ∅ EWTh2 GTAW welding electrode.
• 1
/ 8 " x 1" mild steel strips and 3/ 32 " ∅ ER70S-2.
• 1
/ 8 " x 1" 6061 Aluminum strips and 3/ 32 "∅ 4043 filler rod.
• 100% Argon shielding gas at 20 cfh flow rate.

3. Experimental Procedure
Effects of Electrode Tip Angle

• Grind electrode to small taper angle and then place in welding gun collet so that electrode
extends approximately 1/ 8 " past the nozzle.
• Produce bead-on-plate autogenous welds on a steel plate with 90A DCEN.
• Re-grind the electrode to a larger taper angle and produce the bead-on-plate autogenous welds
on steel plate with 90A DCEN.
• Blunt the electrode (i.e., the taper angle is 1800) and attempt to produce more bead-on-plate
autogenous welds with 90A DCEN.

Results and Discussion: what are the effects of the electrode tip taper angle on the weld bead, the
starting and the stability of the welding arc?

Effects of Arc Length

• Produce bead-on-plate autogenous steel welds but at different gaps between the top surface of
the plate and the tip of the electrode.

Results and Discussion: As the gap is increased, what happens to the voltage, current, the shape of the
arc, the stability of the arc and the general appearance of the weld bead?

1|Page
GTAW Techniques

• Using an assembly of overlapping 1/ 8 " x 1" steel strips, make fillet welds on the lap joint using
a technique by dipping the filler rod into the weld puddle.
• Make some additional weld beads using a technique of rocking the arc across a stationary filler
rod that is laid in the seam.

Results and Discussion: Which technique is preferred and why?

GTAW of Steel and Aluminum

• To GTAW weld aluminum, the machine should use AC current with High Frequency (HF)
option set to Continuous.
• Run beads on aluminum strips by using a circular motion to maintain a 3/ 16 " wide puddle. Try
this first without filler metal and then with the addition of 3/ 32 " 4043 filler rod.
• Try the two previously used techniques of adding filler metals.

Results and Discussion: Is there any defect without filler metal? Did the filler metal eliminate the weld
defect? Describe the weldability differences between aluminum and steel.

2|Page