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GTAW

Fusion Welding Process


Arc Between Non-Consumable Tungsten
Rod And Work
Arc & Weld Pool Shielded By Argon
Filler Wire Separately Added To Weld Pool
Welding Torch & Tungsten Rod Cooled by
Flow OF Argon / Cooling Water
Shielding Gas
Inert Gas - Argon , Helium
Common Shielding Gas Argon
When Helium Is Used Called Heli Arc Welding
When Argon Is Used Called Argon Arc Welding
Inert Gas Prevents Contamination Of Molten Metal
It Prevents Oxidation Of Tungsten Rod
It Ionizes Air Gap and Stabilizes Arc
It Cools Welding Torch & Tungsten Rod
Equipment & Accessories
Pressure Regulator
Flow Meter

Tungsten Rod
Argon Gas In
Cooling Water In Solenoid
Collet Valve Argon Cylinder

Gas Lens
HF Unit &
Welding Cable & Cooling Water Cooling
Ceramic Cup Water In Tube System
Cooling Water Out
Argon Shielding
Arc
High Frequency
+ Connection
Work

Pedal Switch Power Source


+
GTAW Equipment & Accessories
Power Source Inverter, Thyrester,Rectifier,
Generator
High Frequency Unit
Water Cooling System
Welding Torch- (Ceramic Cup, Tungsten Rod,
Collet, Gas-lens)
Pedal Switch
Argon Gas Cylinder
Pressure Gauge, Regulator, Flow Meter
Earthing Cable With Clamp
Types Of GTAW Power Source
Inverter- DC

Thyrester DC

Motor Generator DC

Rectifier DC

Transformer AC (For Aluminium Welding Only)


Power Source
Provides Electric Energy Arc Heat

Drooping Characteristic

OCV Appx. 80V,

Current Range 40 A to 300 A ( Capacity Of M/s)

Arc Voltage 18V to 26V


Characteristic Of GTAW
Power Source
Drooping Constant Current

V
V1
Vertical
V2
Curve

A
A1 A2
High Frequency Unit
Provides High Voltage Electric Energy With
Very high Frequency 10000 Cycles / Sec.

Initiates low energy Arc / Spark & Ionize Air


Gap.

Electrically charges Air Gap For welding


Current to Jump Across the Tungsten Tip &
BM to Form An Arc.

HF Gets Cut Off, Once Welding Arc Struck.


Water Cooling System

Provides Cooling Water To Welding Torch.

Cools Tungsten Rod, Torch handle & Welding


Cable.

Cooling Water Returns through Flexible Tube


Which Carries welding cable within.
Pedal Switch
Sequence

When M/c On
Power source gets energized
Pump starts pumping cooling water to torch
When Pedal Switch Pressed with tungsten rod held close to BM within 3mm
Solenoid valve opens, Argon starts flowing
After 5 seconds of pre-purging, high Frequency current jumps from tungsten
rod generating sparks
Immediately welding current makes arc across tungsten rod and work
through the HF sparks.
High frequency gets cut off from the system when welding arc is initiated and
welding is started.
When Pedal Released without lifting the torch
1 Current gets cut off, Arc extinguishes, Gas flow continues as post purging.
2 Gas flow remains for few more seconds before it stops.
3 Torch to be lifted only after post purging stops
Argon Gas Cylinder- Pressure
Regulator + Flow Meter

Cylinder Stores Argon


Cylinder Valve At High Pressure
Pressure gauges

Regulator Regulates
Flow Meter
Cylinder Pressure to
Flow Regulator Working Pressure
Pressure Regulator
Connection To Torch Flow Meter Controls
Flow Rate
Argon Cylinder
Shielding Gas
Argon - Purity 99.99%

Impure Argon Results In Porosities

Purity Verified by Fusing BQ CS plate

Leakage of Argon in Torch Results in


Porosity.

Check Leakage by Closing the Ceramic


Cup With Thumb
Argon Gas Cylinder
Light Blue In Colour

Full Cylinder Pressure: 1800 psi ( 135 Kgs / Cm2 )

Volume Of Argon In Full Cylinder: 7.3 M3

Commercial Argon (99.99%) Cost: Rs 90/- Per M3

High Purity Argon (99.999) Cost: Rs 110/- Per M3


Back Purging
Purging Gas Commercial Applicable to Single
Argon or Nitrogen Sided full penetration
Prevents oxidation of
Filler Wire Welding Torch root pass from
opposite side of weld
Essential for high
alloy steels,
Purging Purging Gas In nonferrous metals
Gas Out and alloys
Root Pass
Purging Desirable For All
chamber
Material
Tools For GTAW

Head Screen

Hand gloves

Chipping Hammer

Wire Brush

Spanner Set
Tungsten Rod
Tungsten Rod
Non Consumable Electrode.

Maintains Stable Arc

Tip to be Ground to a cone Shape of 60


to 30 angle

Thoriated Tungsten for General


Application, Zerconiated Tungsten for Ground to
Aluminium Welding 50 ankle

Sizes :- 2, 2.4 & 3 mm


Pulsed GTAW
Power Source Provides Two different Current
LevelsBackground and Peakat regular
interval
Background & Peak are above and below
the Average Current
Best Suitable for Full Penetration Open Root
Pass Welding
Ideal for Root Pass by Automatic Machine
Welding
Filler Wire

Added Separately to the weld pool.

Compatible to base metal

Used in cut length for manual welding.

Used from layer wound spool for


automatic welding.

Sizes :- 0.8, 1, 1.2, 1.6, 2, 2.4 & 3 mm


ASME Classification Of Filler Wire
SS Filler Wire:
SFA-5.9, ER 308, 308L, 316, 316L, 347, 309
LAS Filler Wire:
SFA 5.28, ER 70S A1, ER 80S B2, ER90S D2,
ER 80S Ni2
CS Filler Wire:
SFA- 5.18 , ER 70S2
C = 0.07%, Mn = 0.9% 1.4%, Si = 0.4 0.7%, P = 0.025%, S = 0.035%
Dos & Don'ts In GTAW
Dos Donts
Always Connect Dont Strike Arc With
Electrode Ve Electrode + Ve
Keep Always Flow Dont strike Arc Without
Meter Vertical Argon Flow
Check & Confirm Dont Strike Arc By
Argon Purity touching Tungsten Rod
Clean Groove & Filler Dont Touch Weld Pool
wire With Acetone With Tungsten Rod
Grind Tungsten Tip to Dont Lift and break Arc
Point
Dos & Don'ts In GTAW
Dos Donts
Break The Arc Only By When Arc is Stopped
Pedal Switch Dont Lift Torch
Lift The Torch only After immediately.
5 Sec Of Arc Break. Dont Weld With Blunt
Ensure Pre Purging & Tungsten Rod
Post Purging of 5Sec Dont Weld With Argon
Ensure Argon Flow & Leaking Torch
Water Circulation To Dont Weld Without
Torch Water Circulation
Dos & Don'ts In GTAW
Dos Donts
Provide Back Purging Dont Weld Single Sided
For Single Sided Full Full Penetration Welds
Penetration Welds Without Back Purging
Use N2 or Argon as Dont Use N2 As Back
Back Purging Gas For Purging Gas For Non
CS & LAS Ferrous Alloys
Use Argon As Back Dont Empty Ag
Purging Gas For SS & Cylinders Fully.
Non Ferrous Alloys
Defects In GTAW
1. Cracks 2. Lack Of Fusion
3. Porosity 4. Undercut
5.Lack Of Penetration 6. Excess Penetration
7.Overlap 8. Suck Back
9. Under Flush 10. Burn Through
11. Tungsten Inclusion 11.Stray Arcing
Crack
Cause Remedy
1) Wrong Consumable 1) Use Right Filler Wire
2) Wrong Procedure 2) Qualify Procedure
3) Improper Preheat 3) Preheat Uniformly
4) Inadequate Thickness 4) Add More Filler Wire
In Root Pass in root Pass

crack
Lack Of Fusion

Cause Remedy
1) Inadequate Current 1) Use Right Current
2) Wrong Torch angle 2) Train /Qualify welder
3) Improper bead placement 3) Train/Qualify Welder

Lack Of Fusion
Porosity
Cause Remedy
1) Impure Argon Gas 1) Replace Argon Cylinder
2) Argon Leak Within Torch 2) Replace Leaking Torch
3) Defective Filler Wire 3) Replace Filler Wire
4) Wet surface of BM 4) Clean & Warm BM
5) Rusted / Pitted Filler wire 5) Clean Filler Wire
6) Improper Flow Of Argon 6) Provide Gas lens

Porosity . .
Undercut

Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Voltage 2) Reduce Arc length
3) Improper Torch angle 3) Train & Qualify the Welder

Under cut
Lack Of Penetration*
Cause Remedy
1) Excess Root Face 1) Reduce Root Face
2) Inadequate Root opening 2) Increase Root Opening
3) Over size Filler Wire 3) Reduce Filler Wire size
4) Wrong Direction of Arc 4) Train / Qualify Welder
5) Improper bead placement 5) Train / Qualify Welder
6) Improper weaving technique 6) Train & Qualify Welder

* Applicable to SSFPW

LOP
Excess Penetration*
Cause Remedy
1)Excess root opening 1) Reduce root gap
2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase Root face
4) Excess Weaving 4) Train Welder
5) Wrong Direction Of Arc 5) Train Welder
* Applicable to SSFPW

Excess Penetration
Overlap

Cause Remedy
1) Wrong Direction Of Arc 1) Train & Qualify Welder
2) Inadequate Current 2) Increase Current
3) Excess Filler Wire 3) Reduce Filler Metal

Overlap
Suck Back*
Cause Remedy

1) Excess weaving in root 1) Reduce weaving


2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase root face
4) Wrong Electrode angle 4) Train / Qualify Welder
* Applicable to SSFPW in 4G, 3G & 2G

Suck Back
Under flush
Cause Remedy
1) Inadequate weld beads in 1) Weld some more beads
final layer in final layer
2) Inadequate understanding on 2) Train / Qualify welder
weld reinforcement
3) Wrong selection of filler wire 3) Train / Qualify Welder
size

Under flush
Burn through*
Cause Remedy
1) Excess Current 1) Reduce the Current
2) Excess Root opening 2) Reduce root opening
3) Inadequate Root face 3) Increase root face
4) Improper weaving 4) Train / Qualify Welder

*Applicable to root pass

Burn trough
Tungsten Inclusion
Cause Remedy
1) Ineffective HF 1) Rectify HF Unit
2) Improper Starting of Arc 2) Never Touch Weld
With Tungsten Rod
3) Tungsten Tip Comes in 3) Train / Qualify welder
Contact With Weld

Tungsten Inclusion
Stray Arcing
Cause Remedy
1) HF Not In Operation 1) Rectify HF Unit
2) Inadequate Skill of Welder 2) Train the Welder

Arc Strikes

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