0 Types of Welding CurrentThe type of power source determines the type of
current available. The most important factor in selecting the type of current is the type of metal to be welded. The thickness of the metal can also have an influence. You can use either alternating or direct current for both gas tungsten arc welding and high frequency arc ignition, and you may pulse the welding current.3.2.1 Direct CurrentYou can connect direct current in one of two ways: electrode negative (straight polarity)DCEN or electrode positive (reverse polarity)DCEP. The electrically charged particles flow between the tip of the electrode and the work (Figure 9-6). You can use electrode negative for welding all metals. Follow special procedures to weld alloys of magnesium and aluminum, which have a refractory surface oxide that hinders their fusion. You can make welds on aluminum and magnesium with a short arc length using electrode negative and a helium-bearing shielding gas, but you can weld these metals more easily by using electrode positive because this connection breaks down the oxide layers on the surfaces. The main problem with using electrode positive is that the current carrying capacity of the electrode is extremely low. In fact, the electrode will begin to melt if the currents are too high. For this reason, you should rarely use electrode positive except for welding thin sheet metal.3.2.2 Pulsed CurrentThe pulsed current method of TIG employs two levels of welding current instead of a steady current. The welding current switches periodically between the high and low levels to produce a pulsating current or arc. See Figure 9-7 for a diagram of pulsed direct current. This pulsed current produces a continuously welded seam consisting of overlapping arc spot welds. Figure 9-8 shows a cross-sectional view of the pulsed current weld bead. Each of the spots is produced by the high level welding current after which the current is switched to the lower level. This lower level allows the weld to solidify partially between spots and maintains the arc to avoid re-ignition problems. Pulsed current may be used with direct or alternating current, but it is most commonly used with direct current.Figure 9-6 � Negative and positive polarity.NAVEDTRA 14250A9-11 The pulsed direct current method of gas tungsten arc welding has several advantages over steady direct current for welding thin materials. The pulsed method is more tolerant of edge misalignment, normal fixturing can be used with thinner materials, and it gives better distortion control and root penetration. For open root welding, the high pulse provides high current for complete penetration, but the low pulse cools the puddle down to prevent burning through at the root of the joint. Pulsing reduces the heat input to the base metal. This is particularly good for welding thin stainless steel sheet metal, which distorts very easily without pulsed current. Another advantage of pulsed current is that it is very good for welding in the vertical and overhead positions because good penetration is obtainable with less heat input. Pulsing keeps the weld puddle from getting too large to control because of the partial solidification that occurs during the low current. The number of pulses used can vary from about ten per second down to about one or one- half per second. The length of time the high current is on and the length of time the low current is on are variable, as well as the percentage of low current with respect to the high current.3.2.3 Alternating CurrentAlternating current is a combination of both polarities that alternate in regular cycles. In each cycle, the current starts at zero, builds up to a maximum value in one direction, decays back to zero, builds up to a maximum value in the other direction, and decays back to zero. The arc goes out during the zero portion of the cycle, so a high frequency current in the welding circuit reignites the arc. Using alternating current provides the advantages of both direct current electrode positive (reverse polarity) without the current limitations, and direct current electrode negative without the oxide cleaning problems. For this reason, welders generally use alternating current for manual welding aluminum and magnesium. However, in the alternating current circuit, there is a tendency for the current to become unbalanced. The arc current flows more easily in one direction because it takes greater energy to obtain electrons from the base metal than from the tungsten electrode. The Figure 9-8 � Weld produced by pulsed current.Figure 9-7 � Pulsed current terminology.NAVEDTRA 14250A9-12 tungsten electrode emits electrons more easily because it becomes much hotter during welding than the base metal does. The amplitude of the current in the cycle, when the electrode is negative, is normally higher than it is during the cycle when the electrode is positive. This tends to produce an unbalanced current. Operators can use either series connected capacitors or insert a direct current voltage in the welding circuit to balance the current. Balanced current is desirable for some applications like high-speed mechanized welding, but it is not necessary for most manual welding applications. Balanced current flow has three main advantages: 1. Better oxide-cleaning action2. Better and smoother welding action3. N o reduction in the output rating of a conventional welding transformerDisadvantages of a balanced current flow are the following: 1. It requires larger electrodes.2. Wave balancing systems are more expensive.3.2.4 High-Frequency CurrentThe high- frequency current is a separate, superimposed current used to maintain a pilot arc and help start the arc. The pilot arc does not do any welding, but it is needed to start the welding arc without touching the electrode to the work when using either direct or alternating current.When using alternating current, the high frequency current keeps the arc from going out when the alternating current changes cycles, from positive to negative or negative to positive. When using direct current, the high frequency only helps to start the arc and may be turned off after establishing the arc. Using a high frequency current is the best starting method because touching the tip of the electrode to the work or starting on a piece of carbon can contaminate the tungsten electrode. When using this superimposed high frequency current with AC TIG, you need to take certain precautions because the high frequency spark gap oscillators in the power sources radiate power at frequencies that can interfere with commercial, police, and aviation radio broadcasts. It can also interfere with television transmissions. Because of this, the operation of high frequency for AC is subject to control by the Federal Communication Commission in the United States, and most other countries have similar regulations. When installing a welding machine that uses high frequency stabilizers, you must pay special attention to provide earth grounding and special shielding. Manufacturers provide special installation instructions that also require all metal conductors in the area of the machine to be earth grounded. These requirements help limit high frequency radiation. If you follow these instructions carefully, you can post a certificate stating that you reasonably expect the high frequency stabilizer to meet FCC regulations.3.3.0 Types of Power Sources Constant current (cc) machines can produce AC or DC welding power; they can be rotating (generators), static (transformer/rectifier), or three phase machines.inverterNAVEDTRA 14250A9-13 3.3.1 Generator and Alternator Welding Machines For shop use, an electric motor can power a generator welding machine, or an internal combustion engine (gasoline or diesel) can do it for field use. You can adjust generator welding machines intended for shielded metal arc welding to function for gas tungsten arc welding if you add an inert gas and a high frequency attachment. You can adapt engine-driven, either water- or air -cooled welding machines as well, many of which also provide auxiliary power for emergency lighting, power tools, etc. Generator welding machines can provide DC power, and in some cases both AC and DC power to the arc, depending on the machine design. You can also adapt alternator welding machines (also called rotating or revolving field machines) for gas tungsten arc welding. These machines consist of an electric generator made to produce AC power.3.3.2 Transformer-Rectifier Welding Machines Transformer-rectifier welding machines are used much more widely for gas tungsten arc welding than motor-generator welding machines. Transformer-rectifier machines provide both AC and DC welding current to the arc. A single phase transformerproducing alternating current is connected to the rectifier, which then produces DC current for the arc. The rectifier is an electrical device which changes alternating current into direct current. Transformer-rectifier welding machines operate on single phase input power (Figure 9-9), and because of this, an unbalance may be created in the power supply lines, which is objectionable to most power companies.However, this type of welding machine is the most versatile for TIG because you can use it for welding a variety of base metals. A programmable type of transformer-rectifier power source is often used for TIG welding; the welder can select either AC or DC current for the application by simple means of a switch which can change the output terminals to the transformer or to the rectifier.The transformer-rectifier welding machines are available in different sizes and have several advantages over rotating power sources:1. Lower operating costs 2. Lower maintenance costs 3. Quiet operation 4. Lower power consumption while idling 5. No rotating partsFigure 9-9 � Welding machine.NAVEDTRA 14250A9-14 3.3.3 Inverter Power Sources A recently developed machine uses the inverter and different levels of programming. These machines operate on three-phase input power. The three-phase input helps overcome the line unbalance that occurs with the single-phase transformer-rectif ier machines. Inverters provide power down to .5 ampere with a very fast response time of one millisecond and less than 1 % ripple. Different programming is available, depending on the complexity of the job. The high frequency inverters are very quiet and provide outstanding arc stability. 3.3.4 Transformer Welding MachinesTransformer welding machines are not used often for gas tungsten arc welding except at home shops or small job shops where gas tungsten arc welding is used only occasionally. Transformer welding machines produce AC power only and operate on single-phase input power. Like generator welding machines intended for SMAW, you can also adapt transformer welding machines for TIG by adding an inert gas and a high frequency attachment. The transformer welding machine takes power directly from the line, transforms it to the power required for welding, and by means of various magnetic circuits, inductors, etc., provides the volt-ampere characteristics proper for welding. The main advantage of the tra nsformer is that it has the lowest initial investment cost and uses electric power efficiently. However, movable parts tend to vibrate, wear, and become loose, which creates undesirable noise.3.3.5 Square Wave Power SourceTo overcome the arc extinguishing-restriking problem, a square wave AC output power source was developed. Either the conventional constant current type or the constant voltage type of power source can use the square wave output form. In either case, the time for switching from positive to negative or negative to positive current pulse is approximately 50 to 150 microseconds; thus the arc is difficult to restart and is unstable.Power electronics can be used to vary the positive and negative output of the machine. The area above the zero point on the curve (the direct current positive area) and the area below the curve (the negative area) can be equalized or balanced. A power source developed specifically for gas tungsten arc and plasma arc welding provides a square-wave output form but also allows a balance or imbalance between the straight polarity and reverse polarity half-cycles of each cycle. In welding aluminum, the electrode negative (straight polarity half-cycle) gives maximum penetration, whereas the electrode positive (reverse polarity half- cycle) provides for the cleaning action. It is advantageous to provide the most straight polarity half-cycle, and Figure 9- 10 � Square wave output: balanced and unbalanced.NAVEDTRA 14250A9-15 this is possible, as shown in Figure 9-10. This machine also has programming ability and encloses a high-frequency oscillator plus gas and water valves.3.4.0 Controls TIG welding machines have some or all of the following controls to operate the welding: 1. On-off power switch. 2. Polarity selection switch � for machines that produce DC power. 3. Welding current control � a knob or tap switch on the front of the welding machine that controls the amount of welding current delivered to the arc. 4. Foot pedal � an optional piece of equipment for manual welding. It starts the current flow, varies the current during welding, and reduces the current at the end of the weld. This control also starts the high frequency current when high frequency current is used. 5. High frequency control � turns the high frequency current on and off, and selects the type of high frequency current used. Continuous high frequency current is used for AC welding where high frequency current is needed only for arc starting with DC welding current. Also included is a knob to control the amount of high frequency current. 6. Hot start � a knob on some welding machines. When in use, this control causes the machine to furnish momentarily a surge of current substantially above the welding current to get the arc initiated. The knob can also set the amount of �hot start� current required. 7. Pulsation controls. When pulsed current is desired, several controls are usually needed. 8. Up-slope and down-slope controls � optional controls that are timers. The up-slope control allows the welding current to build up gradually at a set rate at the beginning of the welding. The down-slope control allows the welding current to decay gradually at a set rate at the end of the welding to prevent crater cracking. 9. Shielding gas controls � timers that can be set to start the flow of shielding gas before the welding current starts and to maintain gas shielding after the welding arc has been broken. Both of these controls are used to prevent oxidation of the tungsten electrode and contamination of the weld puddle when hot. Several or all of these controls are used with a programmable panel (Figure 9-11) and are available in wide variety depending on the programmer used.Figure 9- 11 � Programmer.NAVEDTRA 14250A9-16