GAS TUNGSTEN ARC WELDING

Dr.P.Sathiya

Gas Tungsten Arc Welding (TIG)

Produced by an electric arc maintain between 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 the atmosphere by a blanket of inert gas fed through the GTAW torch.

Gas serves to blanket the weld, exclude the active properties , does not burn and adds nothing to the bead.

GTAW Process

Produce temperatures of up to 35,000 F Torch contributes only heat to the work piece Filler metal is required to make the weld

Advantage of the GTAW Process

Weld more kinds of metals and metal allow.

Stainless steel, nickel alloys, titanium, aluminum, copper, brass

Also can weld dissimilar metals to each other.

Copper to brass Stainless steel to mild steel.

Other Advantages

Concentrated Arc

Pin point control of heat input to the workpiece. Narrow heat affected zone This is where the base metal has undergone a change due to the superheating of the arc and fast cooling rate.

No Slag No Sparks, Spatter or Noise No Smoke or Fumes

GTAW Disadvantages

Low filler metal deposition rate. Need hand-eye coordination to accomplish the weld Arc Rays are brighter than normal welding. Need additional care to protect skin with proper clothes and welding lens.

Alternating Current

Has both negative and positive half cycles Current flows in one direction during one half of the cycle and reverses directions

Frequency
Rate at which alternating current makes a complete cycle of reversals United States the rate is 60 cycles per second (60 hertz) As frequencies goes up, the arc gets more stable, narrows and become stiffer and more directional.

Types of AC

Sine Wavenormal cycle of AC current Square WaveDone with electronics, ability of positive and negative transition almost instantaneously. Effective use of energy produce a square waveform. Advance Squareware incorporates switching electronics capable of switching currents up to 50,000 times per second.

Types of AC

With the technologyAC is made up of direct current electrode negative and the direct current electrode positive

Direct Current

DCelectrical current that flows in one direction only.

Water flowing through a pipe.

PolarityElectrical charge the electrode is connected for , such as direct current electrode negative (DCEN) or direct current electrode positive (DCEP) Three welding current type and polarity

Direct Current Electrode Negative Direct Current Electrode Positive Alternating Current (combination of both electrode negative and electrode positive polarity.

Direct Current Electrode Negative Straight Polarity

Used for practically all metals. Torch is negative Work is connect to positive Electrons flow from neg. to positive work. 70% of heat on positive side;heat is distributed into the work. Deep penetration

neg

Direct Current Electrode Positive Reverse Polarity

Torch is connect on the positive terminal Work is connected to the negative terminal. Electrons flow from negative to positive, electrode is on the negative side. Electrons are leaving the work. 70% of heat is on positive side and more into the electrode. Electrode has to be large. Used for nonferrous metals, as a cleaning form. USED ON ALUMINUM

Pulsing

Varying the current from a high peak amperage level to a lower background amperage level at regular intervals. Pulse controls also adjust for the number of pulse per second and the percent of time spent at the peak amperage level. Pulsing is used to control heat input and allow for improved weld profile.

Duty Cycle

The number of minutes out of a 10minute time period an arc welding machine can be operated at maximum rated output. An example would be 60% duty cycle at 300 amps. This would mean that at 300 amps the welding machine can be used for 6 minutes and then must be allowed to cool with the fan motor running for 4 minutes.

Shielding Gas

Protects the molten weld pool from the atmosphere. Without this protection, the molten metal reacts with gases in the atmosphere and produces porosity (bubbles) in the weld bead greatly reducing weld strength.

Argon

Obtained as a byproduct in the manufacturing of oxygen. Argon as a liquid temperature is 300 F. Cylinder size 330 cubic feet at 2640 psi at 70 F. Argon provides excellent arc stability and cleaning action. Has low thermal conductivity which means it is not a good conductor of heat. Arc density refers to the concentration of energy in the arc. With argon this energy is confined to a narrow or more pinpointed area.

Preflow and Postflow

To prevent contamination of both the weld pool and the tungsten electrode by the surrounding atmosphere. Preflowwill clear the air and moisture from the torch and prevent this contamination. Postflowprevent oxidization from occurring by shielding the hot electrode and weld area and by speeding up the cooling process. If tungsten that has discolored because of oxidization must be properly removed.

Tungsten Electrode

Color Codes EWCe-2 (2% Cerium, Orange)all purpose electrodes that work with AC or DC electrode negative. Ground to modified Point EWLa-1 Lanthana (Black) Similar performance to thoriated tungsten. Easy arc starting, good arc stability, long life, high current capacity.

Electrode Preparation

Pointed EndUsed for Electrode negativelittle heating affect on the tungsten and a sharp pointed tungsten is preferred. Pointing of electrodes grind the taper for a distance of 2 -2 diameter in length for use on DC & usually to a sharp point. 1/8 electrode ground to to 5/16 long.

Color of electrode
Surface of tungstenshiny and bright. Blue to Purple, blackenedinsufficient postflow of the shielding gas. Postflow rate1 second/10 amps. Contamination of electrodecome in contact between electrode and weld pool or electrode and filler rod.