18
Gas Tungsten Arc and
Plasma Arc Welding
Principles
Chapter Objectives
After completing this chapter, you will be able to:
18-1 Describe the principles of gas tungsten arc welding.
18-2 Describe the principles of plasma arc welding.
18-3 Describe the difference between nonconsumable and
consumable electrode processes.
18-4 Name the essential equipment for GTAW.
18-5 Describe the function of the shielding gas.
18-6 List controls and features found on a GTAW
power source.
18-7 State the proper use of alternating current, DCEN,
and DCEP for GTAW.
18-8 List the proper tungsten to be used for various
applications.
18-9 Describe the GTAW hot wire method.
18-10 Show a properly set up GTAW system.
18-11 Explain the difference between transferred and
nontransferred PAW arcs.
18-12 Explain the main difference between PAW
andGTAW.
Gas Shielded Arc Welding Processes
In the gas shielded arc welding processes, the weld is pro
duced by the arc maintained between the end of a metal
electrode and the part to be welded. The electrode may
be consumable or nonconsumable. A shield of gas ejected
from the torch surrounds the arc and weld region. The
shielding gas may or may not be inert (chemically inac
tive), and pressure is not used. Filler metal may or may
not be added.
History
You have learned that a vital characteristic of sound weld
ing depends on shielding the electric arc and the weld
pool from contamination from the surrounding air. The
first experiments with gas shielding were carried out in
the early 1920s. The development of coated electrodes in
the 1930s eliminated interest in the process at that time.
Welds produced by coated electrodes are actually gas
shielded welds because the electric arc produces a gas as
it burns off the coating.
Coated electrode welding served industry well
through World War II (1945). But when the war ended
and industry began retooling for consumer prod
ucts, competition spurred intensive research and
experimentation to develop new welding methods.
549

Fig. 18-1 Original torch developed by Meredith in 1944. Miller Electric
Mfg. Co.
This effort led to the development of the inert gas
shielded arc welding processes.
In 1930, Henry M. Hobart and Phillip K. Devers of the
General Electric Company were granted patents that cov
ered the basic principle of gas shielded arc welding. In
1944, Russell Meredith of the Northrop Aircraft Company
was issued a patent on the welding of magnesium and mag
nesium alloys. The process was by an electric arc in helium
and argon shielded atmospheres with a tungsten electrode.
One of M erediths original torches is shown in Fig. 181.
Merediths process is the gas tungsten arc process, known
as GTAW or TIG. The process was originally developed
for welding corrosion-resistant and other difficult-to-weld
Fig. 18-2 Welding an aluminum cylinder with the gas tungsten
arc process. Miller Electric Mfg. Co.
550Chapter 18Gas Tungsten Arc and Plasma Arc Welding Principles
metals such as magnesium, stainless steel, and
aluminum. Today it is a standard process (Figs.
182, 183, and 184), widely used in both factory
and field to weld practically all commercial met
als either manually, semiautomatically, mechani
cally, or automatically.
Continued experimentation to make the pro
cess faster led to the development of the gas
metal arc welding (GMAW or MIG/MAG) pro
cess in 1948. It was first applied to the weld
ing of aluminum, and it was found to be several
times faster than the TIG method. By 1951, it
was discovered that by adding a small amount
of oxygen to the argon, the arc action was much
improved and could be applied to the welding
of carbon and stainless steels. Carbon dioxide
was also found to be effective as a shielding gas.
Flux cored and metal cored wires are expan
sions of the basic MIG/MAG process.
Overview of the Processes
There are several gas shielded arc welding processes in
which the welding student should develop skill. These
processes have several of the characteristics of both oxy
acetylene and shielded metal arc welding.
The nonconsumable electrode process, Fig.185,
is known as inert gas shielded, tungsten arc welding.
It is more often referred to as gas tungsten arc
welding (GTAW) or by the shop term tungsten inert
gas (TIG).
Fig. 18-3 A welder putting the finishing touches on a chemical
reactor. He is welding a lining of 116-inch thick pure silver with the
gas tungsten arc process. Nooter Corp.
 Welding Current
Contact Tube

Gas Nozzle

Inert Gas Passage

Metal Electrode
(Filler Metal)
Gas Envelope

Highly Concentrated
Heat

Fig. 18-6 Inert gas shielded, gas metal arc welding (consum-
able electrode).

Fig. 18-4 Mechanized welding on a heavy wall pipe joint with Gas Tungsten Arc Process In the gas tungsten arc pro
the gas tungsten arc welding process and cold wire feed. Arc cess, the heat necessary to melt the metal is provided by
Machines, Inc.
an intense electric arc that is established between a non
Welding Current consumable tungsten electrode and the metal workpiece
Conductor (Collet) (Fig. 187). The electrode does not melt and becomes a
Inert Gas
part of the weld. An edge or corner joint may be fused
With or Passage together without the addition of filler metal, or autogenous
without
Filler Metal Tungsten
welding, using a technique similar to that used with the
Electrode oxyacetylene flame. On joints where filler metal is re
quired, a welding rod is fed into the weld zone and melted
Gas Nozzle
with the base metal in the same manner as that used with
Gas Envelope
oxyacetylene welding. The weld pool is shielded, to pro
tect it, with an inert gas (such as helium or argon, or a mix
ture of the two). The gas is fed through the welding torch.
Gas tungsten arc welding will be our major focus in
this chapter. It is known by such trade names as He-
liarc, Heliwelding, or, as previously noted, the common
shop term of TIG. This process can be used to weld such
Highly Concentrated difficult-to-weld metals as aluminum, magnesium, and
Heat

Fig. 18-5 Inert gas shielded, tungsten arc welding (nonconsum-

able electrode).
The consumable electrode process, shown in
Fig.186, is known as the metal inert gas (MIG) arc
welding process, or, with active gas, as the metal ac-
tive gas (MAG) arc welding process. It is more ap
propriately referred to as GMAW or by the shop term
MIG/MAG.
A method of applying these processes in a semiautomatic
or automatic method is gas shielded arc spot welding; this
method does not require a lot of practice.
A B OU T WEL DIN G
Stick Electrode
The stick electrode is commonly used for
field pipe welding, but it is also possible to use a continuous
welding process. GTAW (TIG) is the best method of applying
the root pass in pipe welding. For the fill and cover passes,
GMAW (MIG/MAG) can be used. Also, flux cored arc welding
(FCAW) can be used. These semiautomatic processes can
be used in the field because it is easy to carry the new
portable feeders.

Gas Tungsten Arc and Plasma Arc Welding Principles Chapter 18551
 Autogenous Welds gas that can be either inert or active. Typical
Made with or
ACHF, DCEN or Gas Nozzle. Either Ceramic without Addition of gases used are argon, helium, oxygen, carbon
DCEP Power or Water-Cooled Metal Filler Metal dioxide, and mixtures of these gases.
Supply
Many Joint Designs A small diameter wire serves both as electrode
Tungsten Electrode
in All Positions Can and filler metal. It is fed into the welding gun auto
Be Welded Easily
Virtually Non- matically, and then into the weld pool at high speed.
consumable
MIG/MAG welding will be studied in Chapter 21.
Weld Surface Compare Figs. 185 and 186 for a basic under
Smooth and Clean
standing of TIG and MIG/MAG welding.
Single Pass Welds Gas Shielded Arc Spot WeldingThe gas
in Thicknesses up
to 1/2; Multipass shielded arc spot welding method is produced
Welds in Heavier with an arc spot pistol grip gun, Fig.188. This
Thicknesses
gun may be provided with a tungsten electrode
Base Metal Can
Be Any Commercial or a consumable electrode.
Weldable Metal Inert Gas Shields The gun makes a weld in the manner shown
Electrode and Weld Pool Work
Connection
in Fig.189. An arc is drawn to the surface of
Weld Possesses Good Quality;
Little or No Loss of Alloying Highly Concentrated Heat (arc) the metal under the protection of the shielding
Elements

Fig. 18-7 Essentials of the gas tungsten arc welding (GTAW)

process. SH OP TA L K

Common Abbreviations
titanium. It can weld dissimilar metals. Because there is CAC-A Air carbon arc cutting
no flux, there is no contaminating residue and no cleaning c.c. Constant current machine
problem. This fact, in itself, results in considerable cost c.v. Constant voltage machine
savings, especially when multipass welding is necessary. c.p. Constant potential machine
Because the shielding gas is transparent, the welder can DCEN (or P) Direct current electrode negative (or positive)
observe the weld pool clearly as it is formed and carried
FCAW-G Flux cored arc welding gas shielded
along during welding. The almost total absence of smoke,
FCAW-S Self-shielded
fumes, and sparks contributes to neater and sounder welds
GMAW Gas metal arc welding
and to the comfort of the welder.
Welding can be performed in all positions. Because GMAW-P Gas metal arc weldingpulse
heat concentration and amperage can be more closely GMAW-S Gas metal arc weldingshort circuit
controlled in TIG welding than in stick electrode welding, GTAW Gas tungsten arc welding
there is less distortion of the base metal near the weld, less HAZ Heat-affected zone
weld cracking, and fewer locked-up stresses. HVOF High velocity oxyfuel
A TIG weld is sound, smooth, strong, ductile, uniform, IR Infrared
and bright. These characteristics make it ideal for use in ISO International Organization for Standardization
industries such as the food business, chemical business, LVOF Low velocity oxyfuel
hospital equipment, and aerospace products. MIG Metal inert gas arc process
MIG-P Pulsed MIG
MPW Magnetic pulse welding
For video of GTAW applications, please visit
OSHA Occupational Safety and Health Administration
www.mhhe.com/welding.
RSW Resistance spot welding
SMAW Shielded metal arc stick electrode welding
Gas Metal Arc Process Gas metal arc welding is a con SAW Submerged arc welding
sumable electrode process. It is also known by such trade THSP Thermal spraying
names as Air comatic, Sigma, Millermatic, and Micro TIG Tungsten inert gas
Wire welding, or, as previously noted, the common shop UV Ultraviolet
term of MIG/MAG. It generally uses DCEP and a shield

552Chapter 18Gas Tungsten Arc and Plasma Arc Welding Principles

 SH OP TA L K

Arc
The space where the electric current jumps
between the end of the electrode and the base metal
is called an arc. It is this gap that causes heat, due to a
resistance of current flow.

Fig. 18-8 Gun for gas shielded arc spot welding GTAW
process. TEC Torch Company

gas. The time of the current flow is controlled so that Tungsten

the arc melts through the surface plate to the plate be Electrode
neath it and forms a weld.
Gas Cup
Gas shielded arc spot welding is used mainly in the
welding of light gauge sheet metal up to 18 inch thick.
Argon Gas
It can be used to weld a wide range of metals, such
as carbon alloy, stainless steels, and most nonferrous Welding Arc
metals. It is used in assembling auto bodies, refrigera
tors, and other home appliances. Figure 1810 shows Gas Vent
a diagram of a manual gas tungsten arc spot welding
system.
Gas shielded arc spot welding has the following advan
tages over resistance spot welding:
It is necessary to have access to only the front side of
the joint.
The equipment is portable and commonly available since Spot Weld

it is also used for MIG/MAG and TIG welding.

Fig. 18-9 Gas shielded arc spot welding.
There is a minimum of spatter, smoke, and sparks.
There is little distortion of the workpiece.
Comparison of the Gas Shielded and Torch Cable
and Hoses Shielding
Shielded Metal Arc Welding Processes I n Gas
any type of welding, the best weld is one that
has about the same chemical, metallurgical,
and physical properties as the base metal.
Trigger
To obtain such conditions, the molten weld
pool must be protected from the atmosphere
during the welding operation. Otherwise, Controls
for Timing
atmospheric oxygen and nitrogen combine Current Flow, Welding
with the molten weld metal and cause a brit Shielding Gas, Power
Cooling Water, Source
tle, porous weld. Tungsten Electrode and
In gas shielded arc welding, the weld zone High Frequency
is protected from the atmosphere by an inert
Slotted Gas Nozzle
gas that is fed through the welding torch. Be
cause of this complete protection from the at
mosphere, welds made by a gas shielded arc Weld Nugget
process are stronger, more ductile, and more
resistant to corrosion than those made by the Fig. 18-10 Diagram of manual gas tungsten arc spot welding system.

Gas Tungsten Arc and Plasma Arc Welding Principles Chapter 18553
shielded metal arc (stick electrode) process. The gas Gas Tungsten Arc Welding
shielded arc processes have the following additional
advantages: If you have mastered oxyacetylene and shielded metal arc
welding, you will have little difficulty learning to weld
The welding heat is confined to a small area. Thus with the common gas shielded arc processes.
there is a narrow heat-affected zone, and faster weld Figure 1811 illustrates the essential equipment needed
ing speeds are possible. Distortion of the welded joint for manual TIG welding:
is reduced. The pure heat source can be used on a TIG torch (A)
great variety of metals. And since no metal is trans Supply of inert gas (B)
ferred across the arc it can be used effectively in all Gas regulator and flowmeter (C)
welding positions. Welds can be made at very high Welding transformer (D)
quality levels. Water supply (E) and return
Welding takes place without spatter, sparks, and
fumes. Therefore, weld finishing is kept to a mini A supply of tungsten electrodes, hose for the gas and
mum. Welds usually require no finishing at all so water, electrical cable, and a fuse assembly or shutoff
that production costs are kept low. valve to protect the torch from overheating are also
There is no need for flux. The absence of slag not only necessary.
reduces the amount of weld finishing, but also pro
duces smoother, nonporous welds. The welder can see Shielding Gases
(and thus control) the weld pool better. From your previous studies, you are familiar with the
The addition of filler metal is by hand and is function of the shielding gas. It permits welding to take
independent of maintaining the arc. Thus it may be place in a controlled atmosphere. In shielded metal arc
added only when neces
sary. Filler metal can
often be eliminated E Water Supply
C Flowmeter and Regulator
when welding thin and or Circulator
medium stock in which D A.C. or D.C. Power
Source
good fitup is secured. For Filler Rod
A Torch
fusion welding the filler
metal should match the
composition of the base
metal. If filler metal is
not added, the welder can
see the weld pool clearly,
thereby improving the
appearance and quality of
the weld.
Work
Fusion welds can be B Inert Gas Supply
made in nearly all com
mon metals. Metals that
can be welded by a gas
shielded arc process in
clude plain carbon and
low alloy steels, cast iron, Power Block
aluminum and aluminum
alloys, stainless steels, Water Drain or Return
to Circulator
brass, bronze, and even
silver. Combinations of
dissimilar metals can also
be welded. Hard-facing
and surfacing materials
can be applied to steel. Fig. 18-11 Typical gas tungsten arc installation.

554Chapter 18Gas Tungsten Arc and Plasma Arc Welding Principles

welding, this is accomplished by placing a coating on
the electrode that produces a protective atmosphere as it
burns in the welding arc. TIG and MIG/MAG welding are
similar in that they surround the arc with gases.
In the gas shielded arc welding processes, however, the
torch (instead of the electrode) supplies the gas. The gas
displaces the air in the arc area before the arc is struck.
Because it will displace air in the arc area, it can also dis
place the breathing air for the welder! These gases can be
odorless and tasteless, so there may be no outward indica
tion of a hazard. If welding in confined or enclosed spaces,
use an oxygen analyzer to check for hazardous conditions.
Weld ContaminationBy volume, air is made up of
21 percent oxygen, 78 percent nitrogen, 0.94 percent argon,
and 0.06 percent other gases (primarily carbon dioxide).
The atmosphere also contains a certain amount of water
vapor, depending upon its humidity at any given time.
There is hydrogen in the water vapor. Of all the elements
that are in the air, the three that cause the most contamina
tion of weld deposits are oxygen, nitrogen, and hydrogen.
Oxygen Oxygen combines readily with other elements in the
weld pool to form unwanted oxides and gases. Deoxidizers,
such as manganese and silicon, combine with the oxygen to
form a light oxide island that floats to the top of the weld pool.
In the absence of a deoxidizer, the oxygen combines with iron
to form compounds that are trapped in the weld metal and
reduce its mechanical properties. Free oxygen also can com
bine with the carbon in the metal to form carbon monoxide. If
carbon monoxide is trapped in the weld metal as it cools, it
collects in pockets. This causes porosity in the weld.
Nitrogen Nitrogen is one of the most serious problems in the
welding of steel materials because there is so much of it in
the air. Nitrogen forms compounds called nitrides during
the welding of steel that cause hardness, a decrease in ductil
ity, and lower impact resistance. These conditions often lead
to cracking in and next to the weld metal. In large amounts
nitrogen also causes serious porosity in the weld metal.
Hydrogen The presence of hydrogen when welding carbon
steels produces an erratic arc and affects the soundness of
the weld metal. As the weld pool solidifies, the hydrogen is
rejected. Part of it, however, is trapped and collects at certain
points where it causes stresses. These stresses lead to small
cracks in the weld metal that may later enlarge. Other frac
ture surface discontinuities such as fish eyes and underbead
cracking may also result from hydrogen contamination.
Inert Gases and Gas Mixtures Generally, argon or he
lium serves well for TIG welding. Mixtures containing
oxygen may be used on some MIG jobs. Oxygen is not
used for TIG welding because tungsten electrodes have a
Gas Tungsten Arc and Plasma Arc Welding Principles Chapter 18555
low tolerance for oxygen; however, small amounts of hy
drogen (17 percent) can be added for special applications.
Argon and helium are both chemically inert. That is,
they do not form compounds with other materials. Thus,
they do not affect tungsten electrodes or the work material.
The welding arc in an atmosphere of either argon or helium
is remarkably smooth and quiet. Many other gases and gas
mixtures have been experimented with, but they all have
some deficiencies such as causing rapid erosion of the tung
sten electrode, porosity in the weld metal, arc instability, or
high cost. Some noninert gases are active and react chemi
cally with some metals, but not with others. For example,
nitrogen can form an effective shield for welding copper.
However, it cannot be used for welding mild steel because,
at arc temperatures, nitrogen causes porosity in the steel
and also forms iron nitrides that embrittle the weld.
If one gas will not provide all the traits desired, a mix
ture will often improve the action of one gas, or combine
the best features of two or more gases. For example, mix
ing argon with helium gives a balance between penetra
tion and arc stability. Adding 25 percent argon to helium
makes penetration deeper than that obtained with argon
alone, and the arc stability approaches that of pure argon.
Tables181, page 556 and 182, page 557 list the perfor
mance characteristics of helium and argon.
Helium and Argon Helium is a product of the natural gas in
dustry. It is found in large quantities in oil and natural gas
fields. Helium is distributed in steel cylinders similar to oxy
gen cylinders. At one time it was used extensively for inflat
ing balloons because of its lightness (next to hydrogen, helium
is the lightest of all gases) and because it is not flammable.
Argon comprises a little less than 1 percent of the Earths
atmosphere. It is a byproduct of the liquefaction of air during
the production of oxygen. Argon is distributed in cylinders
like helium. The cylinders are usually yellow or brown.
Although helium and argon are alike in that they do not
react chemically with other materials, they have differ
ences that are important in welding.
Argon is used more extensively for TIG welding than
helium. It has a smoother, quieter arc and greater clean
ing action in the welding of such metals as aluminum and
magnesium with alternating current.
Helium is more expensive than argon. Its lightness is
also a disadvantage, since it has a tendency to rise from
the weld very rapidly. Two or three volumes of helium
are required to give the equivalent protection of one vol
ume of argon. Thus, helium is consumed in larger quanti
ties, increasing the cost disadvantage. Furthermore, since
argon is denser than helium, the use of argon materially
decreases cylinder handling and reduces the amount of
space required for cylinder storage.
 Table 18-1 Suitability of Argon and Helium for Use as Shielding Gases in Gas Tungsten Arc
Welding of Various Metals1

Argon (with alternating current) is preferred; offers arc stability and good cleaning action. Argon plus
helium (with alternating current) gives less stable arc than argon, but good cleaning action, higher
Aluminum alloys.
speed, and greater penetration. Helium (with DCEN) gives a stable arc and high welding speed on
chemically clean material.

Aluminum bronze. Argon reduces penetration of base metal in surfacing (for which aluminum bronze is used).

Brass. Argon provides stable arc, little fuming.

Cobalt-base alloys. Argon provides good arc stability, is easy to control.

Copper-nickels. Argon provides good arc stability, is easy to control. Used also in welding copper-nickels to steel.

Helium preferred; gives high heat input to counteract thermal conductivity. A mixture of 75% helium
Deoxidized copper. and 25% argon provides a stable arc, gives lower heat input than helium alone, and is preferred for
thin work metal (1 16 in. or less).

Argon provides good arc stability, is easy to control. Helium is preferable for high speed automatic
Inconel.
welding.

Argon preferred for manual welding; success depends on welder skill. Helium preferred for high
Low carbon steel.
speed automatic welding; gives more penetration than argon.

Magnesium alloys. Argon (with alternating current) preferred; offers arc stability and good cleaning action.

Maraging steels. Argon provides good arc stability, is easy to control.

Purified argon or helium equally suitable; welding in chamber preferred, but not necessary if
Molybdenum-0.5
shielding is adequate. For good ductility of the weld, the nitrogen content of the welding
titanium alloy.
atmosphere must be kept below 0.1%, and the oxygen content below 0.005%.

Monel. Argon provides good arc stability, is easy to control.

Argon provides good arc stability, is easy to control. Helium is preferred for high speed automatic
Nickel alloys.
welding.

Helium preferred; provides more uniform root penetration than argon. Argon and argon-helium
PH stainless steels.
mixtures also have been used successfully.

Silicon bronze. Argon minimizes hot shortness in the base metal and weld deposit.

Silicon steels. Argon provides good arc stability, is easy to control.

Stainless steel. Helium preferred. Provides greater penetration than argon, with fair arc stability.

Argon provides good arc stability, is easy to control. Helium is preferred for high speed automatic
Titanium alloys.
welding.

1
Welding is with direct current electrode negative unless noted otherwise.
Adapted from ASM International.
www.asminternational.org.

More heat is liberated at the arc with helium than
argon. Welds of deeper penetration are produced, and
welding is faster. Helium is preferred, therefore, for
the welding of thick sections of steel and for metals
with high thermal conductivity such as aluminum and
copper. Argon, on the other hand, is used extensively
for welding thin metal and dissimilar metals. Its low
thermal conductivity results in a weld deposit with a
relatively wide top bead.
In TIG welding helium produces greater arc voltage
(40 percent) per unit of arc length. This results in a hotter
arc, deeper penetration, and greater welding speeds. It also
reduces the effects of heat on the work. For these reasons
helium is preferred for automatic high production welding.

556Chapter 18Gas Tungsten Arc and Plasma Arc Welding Principles