GAS TUNGSTEN ARC WELDING

The necessary heat for Gas Tungsten-Arc Welding (GTAW), or TIG, is produced by an electric arc maintained
between a non-consumable Tungsten electrode and the part to be welded. The heated weld zone, the molten
metal, and the tungsten electrode are shielded from the atmosphere by a blanket of inert gas fed through the
torch. The GTAW process can produce temperatures of up to 35,000 F. The GTAW torch brings heat only to
the workpiece. If filler metal is desired, it may be added manually like in oxy-acetylene welding or an auto-
matic filler metal feeding system can be utilized.

TIG Applications
The GTAW process has advantages over the other welding processes which in many cases make it more desir-
able to use. Some of these advantages are:
A. HIGHLY CONCENTRATED ARC:
This permits pinpoint control of heat allowing a narrow heat affected zone. A high concentration of heat is an
advantage when welding metals that possess high heat conductivity, such as aluminum and copper. Because of
the highly concentrated arc, some safety precautions should be observed:
1. Unprotected skin is quickly "sunburned" by the arc rays. Eyes should be properly protected by the correct
shade of filter lens. Other workers in the area must be protected from stray glare or flash.
2. When welding in confined areas, such as inside tanks or containers, concentrations of ozone and nitrous
oxides can easily reach an unsafe level. Precautions must be taken to ventilate these areas properly.
B. INERT GAS SHIELDING:
"Inert" means inactive or deficient in active chemical properties. The shielding gas serves only to blanket the
weld and exclude the active properties in the surrounding air. It does not burn, and adds nothing to or takes
anything from the metal. Inert gases like argon and helium, or a mixture of these two, do not chemically react
or combine with other gases. They possess no odor and are transparent permitting the operator maximum visi-
bility of the arc.
C. NO FLUX OR SLAG:
There is no requirement for flux with this process, therefore, there is no slag to obscure the operator's vision of
the puddle. The finished weld will not have slag to remove between passes. Entrapment of slag in multiple
pass welds is not a problem.

Page 1
D. NO SMOKE OR FUMES:
The process itself does not produce smoke or injurious fumes. If the base metal contains coatings or elements
such as lead or zinc that produce fumes, these must be contended with as in any fusion welding process on
these materials. If the base metal contains oil, grease, paint or other contaminants, smoke and fumes will defi-
nitely be produced as the heat of the arc burns them away. The base material should be cleaned to make the
conditions most desirable.
E. NO SPARKS OR SPATTER:
In the GTAW process there is no transfer of metal across the arc. There are no molten globules of spatter to
contend with and no sparks produced if the material being welded is free of contaminants. This is advanta-
geous where spatter would create a problem around the weld or on adjoining parts.
In summary, GTAW welding is a clean process. It is desirable from an operator point-of-view because of the
reasons outlined. The operator must maintain good welding conditions by properly cleaning material, using
clean filler metal, clean welding gloves, and keep oil, dirt and other contaminants away from the weld area.
Cleanliness cannot be overemphasized, particularly on aluminum and magnesium. These metals are more sus-
ceptible to contaminants than are ferrous metals. Porosity in aluminum welds has been shown to be caused by
hydrogen. Consequently, it is most important to eliminate any sources of hydrogen contamination such as
moisture and hydrocarbons.

EQUIPMENT FOR GAS TUNGSTEN ARC (GTAW) WELDING

The equipment required for the Gas Tungsten Arc Welding process may vary with specific applications, but
certain basic components are required, and will be discussed in this manual. The figure below illustrates the
basic components required for gas tungsten-arc welding.

Basic GTAW Equipment

Page 2
 POWER SOURCE
The constant current (drooping volt/amp curve) power source for GTAW welding may be either alternating
current (AC) or direct current (DC). Alternating current is normally used for manual welding of aluminum and
magnesium. Direct current is usually preferred for the ferrous metals and other non-ferrous metals. Some auto-
matic welding applications on aluminum are done with direct current. Amperage requirements may range from
a few amperes to several hundred amperes. The power sources used may be the same ac or ac/dc machine used
for SMAW or depending upon job requirements, may be a sophisticated power supply capable of being pro-
grammed to complete welding automatically.

GTAW Power Sources

GAS TUNGSTEN ARC WELDING POWER

When GTAW welding, the operator has three choices of welding current. They are: direct current electrode
negative (straight polarity), direct current electrode positive (reverse polarity), and alternating current with
high-voltage high-frequency arc stabilization. Each of these current types has its applications, and its advan-
tages and disadvantages. A look at each type and its uses will help the operator select the best current type for
the job.
The type of current used will have a great effect on the penetration pattern as well as the bead configuration.

Page 3
DIRECT CURRENT ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Direct Current Electrode Negative (DCEN) is normally used for GTAW welding
of practically all metals except aluminum and magnesium. The torch is connect-
ed to the negative terminal of the power source and work lead is connected to
the positive terminal. When the arc is established, electron flow is from the neg-
ative electrode to the positive workpiece. In a dc arc approximately 70% of the
heat will be concentrated at the positive side of the arc, therefore the greatest
amount of heat is distributed into the workpiece. This accounts for the deep pen-
etration obtained when using DCEN for GTAW welding. The electrode itself
receives a smaller portion of the heat energy, and will operate at a lower temper-
ature than when using alternating current or direct current reverse polarity. This
accounts for the higher current capacity of a given size tungsten electrode with DCEN than with ac or DCEP.
The electron flow leaving the electrode results in a cooling effect on the tungsten; therefore it operates at a
lower temperature. At the same time the electrons striking the work result in considerable heat being liberated
at this point. The gas ions, which are positively charged, are attracted towards the negative electrode.

DIRECT CURRENT ELECTRODE POSITIVE (REVERSE POLARITY)

When Direct Current Electrode Positive (DCEP) is used the torch is connected
to the positive terminal, and the ground or work lead is connected to the nega-
tive terminal. When using this polarity, the electron flow is still from negative to
positive, however, the electrode is now the positive side of the arc and the work
is the negative side. The electrons now are leaving the work with the same cool-
ing effect as before, and are impinging on the electrode with the resulting heat-
ing effect. The electrode receives the greatest amount of heat and becomes very
hot. The electrode must be large even when low amperages are used to prevent
overheating and possibly melting the electrode. The workpiece receives a small-
er amount of the total heat resulting in shallow penetration. The positive gas
ions are now attracted to the negative workpiece. They strike the work with sufficient energy to chip away the
brittle aluminum oxides and provide "cleaning action." Cleaning action refers to the breaking up and removal
of the oxide coating. Because of this beneficial oxide removal, this polarity would seem to be excellent for
welding aluminum and magnesium. There are, however, some disadvantages. As was previously mentioned
the tungsten electrode becomes very hot, therefore, a large diameter electrode must be used for relatively low
amperage. As an example, a 1/4" diameter electrode would be necessary to weld with DCEP at 125 amperes.
The large diameter electrode will naturally produce a wide puddle resulting in the heat being widely spread
over the joint area. If DCEN were used at 125 amperes, a 1/16 diameter electrode would be adequate. The
small electrode produces a more highly concentrated arc resulting in the heat energy being confined to a small-
er area.
Since most of the heat is liberated in the electrode, the resulting penetration pattern will prove to be shallow
when using DCEP. When used on aluminum the arc would be somewhat erratic as aluminum is not a good
emitter of electrons.
The good cleaning action of electrode positive, plus the stable arc and good penetration of electrode negative,
would seem to be the best combination for welding aluminum. A compromise to obtain the advantages of both
DCEN and DCEP is to use alternating current.

Page 4
ALTERNATING CURRENT
When using alternating current the terms positive and negative which were
applied to the workpiece and electrode lose their significance. The current is
now alternating or changing its direction of flow. During a complete cycle of
alternating current there is theoretically one half cycle of electrode negative and
one half cycle of electrode positive. Therefore, during a cycle there is a time
when the work is positive and the electrode is negative and a time when the
work is negative and the electrode is positive. In theory, the half cycles of alter-
nating current are of equal time and magnitude. When alternating current is
applied to GTAW welding of aluminum, this is not necessarily true. Tests show
that the half cycles are unbalanced, the electrode positive half cycle being of
lesser magnitude. The reason this occurs is because of the aluminum oxide on the workpiece. The surface
oxide acts as a rectifier, much like a rectifier used in a welding power source to change ac to dc. The oxide
makes it difficult for the electrons to flow from the work to the electrode but has little affect on electron flow
from the electrode to the work. The high temperature incandescent tip of the tungsten electrode is a better elec-
tron emitter than the large aluminum surface, which is at a much lower temperature. This results in a larger
amount of current flow during the electrode negative half cycle than during the electrode positive half cycle.
The question arises, what happened to the other part of the electrode positive half cycle? It was rectified by the
aluminum oxide and became direct current electrode negative, and is conducted by the welding leads back to
the power source. The condition described is referred to as "dc component" and exists whenever welding is
done on materials with an oxide coating like aluminum and magnesium. Once the dc component is back to the
power source it is dissipated as heat in the main transformer. Heating in the main transformer causes at least
two serious problems:
1. Breakdown of insulation on the coils and core material.
2. Decrease in efficiency of the transformer due to the higher resistance of the heated coils and core.

Characteristics Of Current Types For Gas Tungsten Arc Welding

Page 5
 SQUARE WAVE ALTERNATING CURRENT BALANCED AND UNBALANCED
WAVE FORMS
Modern square wave AC GTAW solid state controlled power sources have the ability to rapidly make the tran-
sition between the positive and negative half cycles of alternating current. When welding with alternating cur-
rent, the faster the transition is made between the two polarities, a more stable arc is possible.
The front panel squarewave balance control potentiometer controls these kinds of power sources and may
allow the length of time the machine spends in either the positive or negative portion of the AC cycle to be
changed. Modifying or changing the AC cycle produces what is known as an unbalanced sine wave. There are
advantages to welding on an unbalanced sine wave.
UNBALANCED SQUARE WAVE AC ADVANTAGES:
1. Excellent oxide cleaning is obtained because of the strong positive half cycle.
2. Higher currents can be used with a given size electrode because the positive half cycle that heats the
electrode can be of less duration.
3. Deeper penetration than with the balanced wave because penetration occurs during the negative half
cycle. Adjusting the balance control to provide an increase in the negative half cycle will accomplish
this.
Note that square wave ac balance occurs at the control setting of 30 rather than at 50. This is because as the
control setting is moved toward maximum cleaning a point is reached where additional time in the positive
half cycle is unproductive and will result in damage to the tungsten electrode or possibly the torch. Therefore,
most adjustable square wave machines will not permit adjustment beyond 55% electrode positive half cycle.
This setting allows the current to spend more time in the positive half cycle where current flow is from the
work to the tungsten, and maximum cleaning is achieved. Note how the maximum cleaning setting ratio of
positive to negative half cycle is much less at the maximum cleaning setting than it is at the maximum pene-
tration setting. (55% electrode positive and 45% electrode negative for maximum cleaning; and 32% electrode
positive and 68% electrode negative for maximum penetration) Only a certain amount of total cleaning action
is achievable with the electrode positive half cycle. Increasing the time in the electrode positive half cycle
beyond this point will not provide more cleaning, but may melt the tungsten and possibly damage the torch.

Page 6
HIGH-VOLTAGE HIGH-FREQUENCY ARC STARTER AND STABILIZER
Tests have shown that a higher open circuit voltage than the 70-80 volts normally available from the power
source will assure reignition as the current passes through zero. About double the normal voltage will assure
reignition. This is where the high frequency high voltage source becomes necessary in the circuit. Several
thousand volts but with a fraction of an ampere of current is imposed into the secondary circuit. The high volt-
age is sufficient to reignite the positive half cycle which in turn provides the oxide removal. A common misun-
derstanding is that the high frequency does the cleaning. This is NOT true. It serves to reignite the arc which
does the oxide removal. The ac cycle is still unbalanced, however, the arc is stabilized by assuring reignition
and the positive half cycle is available for oxide removal.
High frequency serves to start the arc initially without making contact to the work with the electrode. On
materials sensitive to impurities touching the tungsten to the work will contaminate the work and the tungsten.
Aluminum and magnesium are such materials. A "non-touch" start is essential on these materials. When weld-
ing steel, stainless steel, brass, etc. with direct current it may also be desirable to establish the arc without
touching the work. A high frequency start may be used where the high frequency is on only until the arc is
established and then is removed from the circuit automatically. When GTAW welding with direct current the
"scratch" start is frequently used. The arc is established by touching the electrode to the work much the same
as striking an arc with a stick electrode.
Another purpose of high frequency is for gas ionization. The high voltage promotes ionization of the shielding
gas providing a good path for the current to follow. The term "ionization" means the gas atom has lost one or
more of its electrons leaving the atom positively charged. When the work is negative the positive gas ion is
attracted to it. The gas ion strikes with sufficient force to chip away the brittle aluminum oxides. This can be
compared to a sandblasting operation and cleaning can easily be observed when welding aluminum. It can be
said then that high frequency has three important functions: (1) arc initiation - non touch starting, (2) arc stabi-
lization - reignition of the positive half cycle when ac welding and (3) gas ionization - aids starting and pro-
motes cleaning action.
Machines which are specifically designed for GTAW welding usually have a "built-in" high frequency unit.
The unit contains several components. The main parts are a step-up transformer, capacitors, a set of spark gap
points, a rheostat, and a coupling coil to induce the high frequency into the welding circuit.
When it is desirable to use an existing power source for GTAW welding and high frequency is necessary, a
separate unit may be connected into the welding circuit. The following figure illustrates such a unit which con-
tains the components mentioned above, plus water and gas controls. This unit can be coupled to a dc or ac/dc
motor generator, ac transformer, dc rectifier, or ac/dc rectifier type welders.

Typical Process Connections

Page 7
 HIGH FREQUENCY
When high frequency is used with AC GTAW, certain precautions are required to prevent interference with
communications equipment. The following identifies sources of high frequency radiation from incorrect instal-
lation and the correct installation.

WARNING
HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers,
and communications equipment.
Have only qualified person familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and
shielding as shown in Figure 3 to minimize the possibility of interference.

1 Gas Tungsten Arc Torch

1 2 High-Frequency Voltage
Used to help arc jump air gap
3 between torch and workpiece and/
or stabilize the arc.
4
2 3 Submerged Arc Welding Gun
5
4 Flux
Work Work 5 High-Frequency Voltage
Used to help arc reach workpiece
Gas Tungsten Arc Submerged Arc through flux granules.
Welding (GTAW) Welding (SAW) S-0693

Welding Process Requiring High Frequency

1 Sources Of Direct
Weld Zone High-Frequency Radiation
3 High-frequency source (welding
power source with built-in HF or
50 ft separate HF unit), weld cables,
(15 m) 3 torch, work clamp, workpiece, and
work table.
2 Sources Of Conduction Of
3 High Frequency
3 2 Input power cable, line disconnect
device, and input supply wiring.

1 3 Sources Of Reradiation Of
High Frequency
Ungrounded metal objects, light-
1 ing, wiring, water pipe and fixtures,
external phone and power lines.
2

S-0694

Sources Of High Frequency Radiation From Incorrect Installation

Page 8
 7
Weld Zone

3 50 ft
(15 m) 50 ft
(15 m)

1
6

2
9

9 Ground All
Metal Objects
And All Wiring
In Welding Zone
Using #12 AWG Wire
Ground
Workpiece
If Required
By Codes
Nonmetal
Building
8

9
9
11

Metal Building

10

1 High-Frequency Source (Welder With
Built-In HF Or Separate HF Unit)
Ground metal machine case, work output
terminal, line disconnect device, input
supply, and worktable.
2 Center Point Of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
S-0695
5 Conduit Joint Bonding 9 Grounding Rod
Electrically join (bond) all conduit sections
using copper straps or braided wire. Ground Consult the National Electrical Code for
conduit every 50 ft (15 m). specifications.
6 Water Pipe And Fixtures
10 Windows And Doorways
Ground water pipe every 50 ft (15 m).
7 External Power Or Telephone Lines Cover all windows and doorways with
grounded copper screen of not more than
Locate high-frequency source at least 50 ft 1/4 in (6.4 mm) mesh.
(15 m) away from power and phone lines.
8 Metal Building Panel Bonding 11 Overhead Door Track
Methods
Bolt or weld building panels together, install Ground the track.
copper straps or braided wire across
seams, and ground frame.

Correct Installation

Page 9
 OTHER METHODS OF ARC STARTING
High frequency is not the only method of starting and stabilizing the welding arc. Capacitive discharge circuits
on DC only machines produce a high voltage discharge from a bank of capacitors to establish the arc. The
momentary spark created by these machines is like a static discharge. Although capacitive discharge machines
have good arc starting capability, they do not have the arc stabilization properties of high frequency machines
so these power sources are for only direct current.
Pulse mode arc starting and stabilizer circuit machines utilize special circuitry to impose a short duration high
intensity pulse of voltage on the output circuit when the output load voltage is at a specific value. A machine
provides or generates this pulse only when the output voltage is greater than 30 volts. When not welding, volt-
age (or pressure) is at maximum because no current is being allowed to flow and the pulsing circuitry is
enabled. As the electrode is brought near the work the voltage pulses help the arc jump the gap and welding
begins. Once the arc is started, weld circuit load voltage typically drops to about 14 volts and the pulsing cir-
cuit senses this change and drops out. The pulse mode circuitry can also help stabilize the AC arc because it is
enabled during times the voltage sine wave is transitioning through zero. The high intensity voltage pulses do
affect other electronic circuitry in the immediate vicinity, but the effect is not as pronounced as that of a high-
voltage high-frequency arc starter power source.

Lift Arc
Welding where the use of high frequency for arc starting is not allowed or is not available may require a
scratch or touch start technique. The scratch start technique creates an arc by scratching the tungsten lightly on
the workpiece like a match. Or the tungsten may be touched to the workpiece and pulled away slightly to
establish the arc. The high open circuit voltage of the power source is present as the tungsten touches the
workpiece. This creates the tendency to stick or weld itself to the workpiece.

Lift Arc GTAW is a specially designed circuit that limits voltage to a low sensing voltage and the short circuit
current is limited while the tungsten is touching the workpiece. After the tungsten is lifted and the arc is estab-
lished, the amperage goes to the amperage set on the power source. This allows low-amperage contact (touch)
GTAW arc starting without sticking or contamination and without high frequency when using direct current.

Lift Arc Technique

Page 10
 COOLING SYSTEMS
When applications call for high amperages, or when welding continuously, a water cooled torch and cable
assembly may be used. The water is brought to the torch through a hose, circulates through the torch, and is
returned through another hose, which also contains the power cable. The power cable will be considerably
smaller than the work cable being used. This is possible because the cooling water returning from the torch
cools the cable and allows it to carry a much higher amperage. This wouldn't be possible if it were not cooled.
Cooling water may be supplied from individual self-contained cooling systems.
The type of cooling system termed "individual self-contained" consists of a tank, an electric motor, and a high
pressure pump to circulate the water. The pump runs all the time the machine is on and recirculates the water
through the system. Care must be taken to prevent water from freezing. Where freezing conditions may be
encountered, a mix of distilled water and pure ethylene glycol may be used. A mix of distilled water and pure
ethylene glycol has sufficient lubricative qualities for adequate pump lubrication.
The figure below shows a typical cooling system such as would be used on a single torch. It consists of a
pump, holding tank and radiator.

Typical Single Torch Cooling System

TORCHES
The torch used for GTAW welding may be either water or air cooled. High production or high amperage torch-
es are usually water cooled while lighter duty torches for low amperage applications may be air cooled. The
water cooled torch is designed so that water is circulated through the torch cooling it and the power cable. The
power cable is contained inside a hose, and the water returning from the torch flows around the power cable,
thereby cooling it. In this way the power cable can be relatively small making the entire cable assembly light
and easily maneuverable by the operator. When using a water cooled torch a lack of cooling water or no cool-
ing water at all will cause a heat build-up and will probably cause the polyethylene sheath to melt or possibly
burn the power cable in two. A torch manufacturer's specifications will designate the required amount of cool-
ing water for a specific torch. A safety device known as a "fuse assembly" can be installed in the power cable.
This assembly contains a fuse link which is also cooled by the water. If there is no cooling water circulating,
the fuse link will melt in two and prevent damage to other more expensive components. The fuse link is easily
replaced. When the fuse link is replaced and water flow is maintained, welding can continue.
Air cooled torches are popular for lower amperage applications. They require no additional cooling other than
the surrounding air and the flow of the relatively cool shielding gas through the torch. The power cable must
be heavier than the cable in a water cooled torch. The power cable may be wound around the gas carrying
hose or inside the gas hose.

Page 11
 Required Torch Parts
The tungsten electrode diameter and type will vary depending on the metal being welded and current require-
ments. Each diameter of tungsten will require a collet, collet body and gas cup (nozzle) size to correspond
with the tungsten diameter size used.
Torch & Power Cable
Connected to the welding machine's electrode or negative welding output terminal.
Collet Body
Threads into the head of the torch and aligns the tungsten in the gas cup (nozzle).

Gas Cup (Nozzle)

Attached to the collet body, either threaded or held in place by friction fit. Directs shielding gas flow to the
weld area.

Collet
Inserted into collet body and secures the tungsten electrode by threading and tightening the back cap.

Back Cap
Secures tungsten by threading into torch head and tightening the collet against the collet body. Backcaps are
sold in different lengths to allow the welder to access different joints and positions.

Page 12
 Torch Backcaps

7 1 Cup
Torch Assembly 6
4 5 2 Collet Body
3
2 3 Heat Shield

1 4 Torch Body
OR
5 Standard Collet
8 6 O-Ring
7 Backcap
8 Reverse Collet
9 Tungsten Electrode

Tungsten Installation

Loosen Tighten
9

Distance = Tungsten Diameter

ST-157 713-A

Torch Assembly And Tungsten Installation

TUNGSTEN ELECTRODES
Electrodes used for GTAW welding differ greatly in many respects from electrodes used in shielded metal arc
welding. The tungsten electrode is not melted and used as filler metal as in the case with stick electrode weld-
ing. At least it is not intended to be melted and become part of the deposit. However, in cases where the wrong
electrode type, the wrong size of electrode, the wrong current or technique is used, tungsten particles
may be transferred across the arc. The power source used may affect the amount of tungsten which may be
transferred across the arc. A machine designed specifically for GTAW welding will usually have a characteris-
tic sine wave shape or volt/amp output characteristic advantageous for the process. Excessive current surges or
"spikes" will cause "spitting" of tungsten. Excessive arc rectification on aluminum or magnesium will cause a
"half-wave" effect, and cause particles of tungsten to be transferred across the arc. An understanding of the
electrode materials and the types of electrodes and their recommended uses will enable the user to make the
proper electrode selection.

Page 13
Tungsten is a very hard, steel gray colored metal. It is a highly refractory (a melting point exceeding 3600 F)
metal and does not melt or vaporize in the heat of the arc. It has a melting point of 6170 F, and a boiling
point of 10,700 F. Tungsten retains its hardness even at red heat. It has the highest melting point of all metals.
Tungsten electrodes for GTAW welding come in a variety of types, sizes, and lengths. They may be either pure
tungsten or tungsten alloys. The alloying elements used are thorium, cerium, lanthanum, or zirconium oxide.
Electrodes are manufactured to specifications and standards developed by the American Welding Society, and
the American Society for Testing and Materials. Electrodes come in standard diameters from 0.010" through
1/4" and lengths from 3" to 24."

SELECTION
With the choice of several alloy types and a variety of types and sizes, many factors must be considered when
selecting the electrode. One of the main considerations is the type and amount of welding current. The welding
current will be determined by several factors including: base metal and thickness, joint design, fit-up, position,
shielding gas, type of torch, and other job quality specifications.
An electrode of a given diameter will have its greatest current carrying capacity with direct current, electrode
negative (straight polarity), less with alternating current and the least with direct current electrode positive
(reverse polarity). Tungsten has a high resistance to current flow and, therefore, heats up during welding. In
some applications the extreme tip forms a molten hemisphere. The "balled" tip is characteristic of pure tung-
sten and is most desirable for ac welding. The extreme tip is the only part of the electrode which should be this
hot. The remainder of the electrode should be kept cool. Excessive electrode stickout beyond the collet will
cause heat build-up in the electrode. In a water cooled torch the heat is more rapidly dissipated from the collet
assembly and helps cool the electrode. Excessive current on a given size electrode will cause the tip to become
excessively hot and melt.
All tungsten electrodes will do a welding job and may be used in a similar manner. Electrodes of each classifi-
cation have distinct advantages with regard to operating characteristics and usability. The advantages and char-
acteristics of each type will be discussed to aid in selecting the best electrode for the application.

Color Code And Alloying Elements For Various Tungsten Electrode Alloys
Nominal Weight Of
Alloying Oxide
AWS Classification Color* Alloying Element Alloying Oxide Percent
EWP Green
EWCe-2 Orange Cerium CeO2 2
EWLa-1 Black Lanthanum La2O3 1
EWTh-1 Yellow Thorium ThO2 1
EWTh-2 Red Thorium ThO2 2
EWZr-1 Brown Zirconium ZrO2 .25
EWG Gray Not Specifiedb
a. Color may be applied in the form of bands, dots, etc., at any point on the surface of the electrode.
b. Manufacturer must identify the type and nominal content of the rare earth oxide addition.

Page 14
 Recommended Tungsten Electrodesa And Gas Cups For Various Welding Currents

Direct Current, A Alternating Current, A

Use Gas Electrode Electrode Unbalanced Balanced
Electrode Diameter Cup I.D. Negativeb Positiveb WaveC WaveC
in. mm in. DCEN DCEP
0.010 0.25 1/4 up to 15 up to 15 up to 15
0.020 0.50 1/4 5-20 5-15 10-20
0.040 1.00 3/8 15-80 10-60 20-30
1/16 1.6 3/8 70-150 10-20 50-100 30-80
3/32 2.4 1/2 150-250 15-30 100-160 60-130
1/8 3.2 1/2 250-400 25-40 150-210 100-180
5/32 4.0 1/2 400-500 40-55 200-275 160-240
3/16 4.8 5/8 500-750 55-80 250-350 190-300
1/4 6.4 3/4 750-1100 80-125 325-450 325-450
a. All values are based on the use of argon as the shielding gas.
b. Use EWTH-2/EWCe-2 electrodes.
c. Use EWP/EWZr-1 electrodes.

PURE TUNGSTEN (EWP)

Pure tungsten electrodes are usually preferred for ac welding of aluminum and magnesium because they form
the ball or hemispherical end. They provide good arc stability on ac with both argon and helium shielding.
They can also be used with direct current, but the current carrying capacity is lower than alloyed electrodes.
On critical applications, pure tungsten has reasonably good resistance to contamination, however, there is more
of a tendency to drop tungsten particles across the arc. Starting characteristics are not as good as with the
alloyed type, particularly at low amperages. Pure tungsten electrodes are identified by a green color band.

THORIATED TUNGSTEN (EWTH)

The addition of a small percentage of thorium oxide (thoria) adds desirable characteristics to the electrode.
Thoria increases the electron emission qualities of the electrode which gives it a better starting characteristic
and a higher current carrying capacity. The addition of 1% to 2% thoria increases the maximum current carry-
ing capacity by approximately 50% for a given size electrode on alternating current. The thorium alloyed tung-
sten electrode does not ball as does the pure tungsten; rather it forms several small projections across the face
of the electrode when used on alternating current. When used on ac the arc wanders between the multiple pro-
jections or nodes and is often times undesirable for proper welding. This electrode is usually preferred for
direct current applications. In many dc applications the electrode is ground to a taper or pointed. The thorium
alloyed tungsten electrode will retain the desired shape in these applications where the pure tungsten would
melt back and form the ball end.
Most popular of the thoriated type are the 2% thoriated. These are identified by a red color band. The 1% tho-
riated are identified by a yellow band.

ZIRCONIUM ALLOYED (EWZr-1)

Zirconium alloyed tungsten is desirable for ac welding applications because of its high resistance to contami-
nation as well as good arc starting characteristics. These electrodes form a hemispherical or "balled" end like
the pure tungsten. Primarily these electrodes are recommended for welding conditions where the highest quali-
ty work is necessary and where even the smallest amounts of weld puddle contamination cannot

Page 15
be tolerated. Zirconium alloyed tungsten produces a stable arc and resists arc spitting. Their current carrying
capacity is equal to or slightly greater than an equal size thorium alloyed electrode. These electrodes are iden-
tified by a brown color band.

Amperage Range - Gas Type - Polarity

Electrode Diameter DC Argon Electrode DC Argon Electrode AC Argon Using AC Argon Balanced
Negative/Straight Polarity Positive/Reverse Polarity High Frequency Wave Using High Freq.
Pure Tungsten
(Green Band)
.010 Up to 15 * Up to 15 Up to 10
.020 5-20 * 5-20 10-20
.040 15-80 * 10-60 20-30
1/16 70-150 10-20 50-100 30-80
3/32 125-225 15-30 100-160 60-130
1/8 225-360 25-40 150-210 100-180
5/32 360-450 40-55 200-275 160-240
3/16 450-720 55-80 250-350 190-300
1/4 720-950 80-125 325-450 250-400
2% Thorium Alloyed
Tungsten (Red Band)
.010 Up to 25 * Up to 20 Up to 15
.020 15-40 * 15-35 5-20
.040 25-85 * 20-80 20-60
1/16 50-160 10-20 50-150 60-120
3/32 135-235 15-30 130-250 100-180
1/8 250-400 25-40 225-360 160-250
5/32 400-500 40-55 300-450 200-320
3/16 500-750 55-80 400-500 290-390
1/4 750-1000 80-125 600-800 340-525
Zirconium Alloyed
Tungsten (Brown Band)
.010 * * Up to 20 Up to 15
.020 * * 15-35 5-20
.040 * * 20-80 20-60
1/16 * * 50-150 60-120
3/32 * * 130-250 100-180
1/8 * * 225-360 160-250
5/32 * * 300-450 200-320
3/16 * * 400-550 290-390
1/4 * * 600-800 340-525

Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
*Not Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers. S-0009

Tungsten Size

Page 16
 PREPARING, USE AND CARE OF TUNGSTEN ELECTRODES
After the proper size and type of electrode has been selected, how the electrode is used and maintained will
determine its performance and life. There are many misconceptions about tungsten electrodes and their correct
use. The following information is intended to serve as a guideline to "common sense" decisions about tungsten
electrodes.

Forming A Ball On The Electrode

The electrode tip can be balled by striking an arc on a copper block or other suitable material using AC or
DCEP. Arc current is increased until the end of the electrode turns white hot and begins to melt, causing a
small ball to form. The current is decreased and turned off, leaving a hemispherical ball on the end of the
tungsten electrode.

Ball end of tungsten before weld-

ing by applying either an AC
amperage slightly higher than
what is recommended for a given
electrode diameter, or a DC elec-
trode positive amperage.

Preparing Tungsten For AC Welding

On electrodes that form a hemisphere or ball end, the diameter of the end should not exceed the diameter of
the electrode by more than 1-1/2 times. As an example, a 1/8" electrode should only form a 3/16" diameter
end. If it becomes larger than this because of excessive current, there is the possibility of it dropping off to
contaminate the weld. If the end is excessively large, and the current is decreased before the molten tip drops
off, the arc tends to wander around on the large surface of the electrode tip. The arc becomes very hard to con-
trol as it wanders from side to side. If welding conditions are correct, a visual observation of the electrode
should reveal a ball end of uniform shape and the proper size. The surface of the ball should be shiny and
bright. If it appears dull, an excess of current is indicated. If it appears blue to purple or blackened, there is
insufficient post-flow of the shielding gas. This means the surrounding atmosphere oxidized the electrode
while still hot, and it is now contaminated. Continuing to weld with this condition can only result in the oxide
flaking off and ending up in the weld deposit. A general rule for post-flow is one second for each ten amperes
of welding current. This is normally adequate to protect the tungsten until it cools below its oxidizing tempera-
ture.
Contamination of the electrode can occur in several ways in addition to the lack of post-flow shielding gas.
The most common form of contamination is contact between electrode and weld puddle or electrode and filler
rod. Loss of shielding gas or contamination of the shielding gas due to leaking connections or damaged gas
hoses causes electrode contamination. Excessive gas flow rates and nozzles that are dirty, chipped or broken
cause turbulence of the shielding gas. This aspirates atmospheric air into the arc area causing contamination.
The electrode that has been contaminated by contact with the puddle or filler rod will have a deposit of the
metal on the electrode. If this is not too serious, maintaining an arc on a scrap piece of material for a period of
time may vaporize the deposit off the electrode. If the contamination cannot be removed in this manner, the
contaminated portion should be broken off and the electrode re-shaped as desired.

GRINDING
Grinding of electrodes is common practice and is sometimes used to remove contamination. Grinding tech-
niques are important and many times poor grinding techniques can cause problems. Grinding should be done
on a fine grit, hard abrasive wheel.
Page 17
Tungsten is harder than most grinding wheels, therefore, it is chipped away rather than cut away. The grinding
marks should run lengthwise with the point. If the grinding is done on a coarse stone and the grinding marks
are concentric with the electrode, there are a series of ridges on the surface of the ground area. There is a pos-
sibility of the small ridges melting off and floating across the arc. If the stone used for grinding is not clean,
contaminating particles can be lodged in the grinding crevices and dislodged during welding, and end up in the
deposit. The grinding wheel used on tungsten electrodes should be used for no other material.
A common practice in pointing electrodes is to grind the taper for a distance of 2 to 2-1/2 electrode diameters
in length. Using this rule for a 1/8" electrode the ground surface would be 1/4 to 5/16" long. In some applica-
tions a sharp needle point is preferred to aid low amperage starting. Needle pointed electrodes are usually pre-
ferred also on very thin metals in the range of 0.005" to 0.040." In other applications a slightly blunted end is
preferred because the extreme point may be melted off and end up in the deposit. In many applications point-
ing is done where actually a smaller electrode should be used.

CAUTION
FLYING SPARKS AND HOT METAL can cause injury and start fires.
Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
Keep flammables away.
warn2.1 9/91

Preparing Tungsten For DC Electrode Negative (DCEN) Welding

CHEMICAL SHARPENING
Chemical sharpening consists of submerging or dipping the red-hot end of tungsten electrode into a container
of sodium nitrate. The chemical reaction between the hot tungsten end and the sodium nitrate will cause the
tungsten to erode at a uniform rate all around the circumference of the electrode. Repeated heating and dipping
will form a tapered tip.

Page 18
 SHIELDING GASES
The use of gas shielding to prevent contact of the surrounding atmosphere and the molten metal during weld-
ing is not new. From the time the oxy-acetylene process was first used, gas shielding was an inherent charac-
teristic. The combustion of the fuel gas and oxygen provided, in addition to heat, gaseous products such as
carbon monoxide, carbon dioxide and water vapor. These gases served the function of protecting the molten
weld metal. When covered electrodes were developed, elements were incorporated into the coating which
when decomposed in the heat of the arc produced mainly carbon dioxide and carbon monoxide. They serve as
shielding media, and also contribute to stabilization of the arc.
With the GTAW process no flame is present to produce any shielding effect and there is not a flux coating of
any kind to form a shielding gas. Consequently, an external source of shielding is necessary.
Primarily two inert gases are used for shielding purposes. They are argon, helium, or a mixture of the two.
They must be of high purity for welding applications. The purity is normally held to 99.995%. Each of these
gases have characteristics which must be understood in making a selection of a shielding gas for a particular
application. The primary function of the gas is to exclude the active properties in the surrounding air from the
weld area. The type of gas also has an influence on the characteristics and behavior of the arc and resultant
weld. The chief factor influencing the effectiveness of a shielding gas is the gas density. Argon with an atomic
weight of 40 is about one and one third times as heavy as air and ten times as heavy as helium with an atomic
weight of 4. Argon after leaving the torch nozzle tends to form a blanket over the weld area whereas helium
tends to rise rapidly from the arc area. In order to obtain equivalent shielding, flow rates for helium are usually
two to three times that of argon. The same is true of helium-argon mixtures, especially those with high helium
content.
An examination of the characteristics of each gas and a comparison of these characteristics will serve as a
guide to shielding gas selection.

ARGON
Argon may be obtained in the gaseous state in cylinders or as a liquid in specially constructed cylinders or
bulk tanks. As a liquid, argon will be at a temperature of slightly below -300 F. The most commonly used size
of cylinder contains 330 cubic feet at 2640 p.s.i. at 70 F. When large volumes are required a bulk liquid sup-
ply is most desirable and economical. Each gallon of liquid will produce approximately 112 cubic feet of
gaseous argon.
The ionization potential of argon is 15.7 volts. Ionization potential is the voltage necessary to remove an elec-
tron from the gas atom making it an ion or charged atom. Argon has low thermal conductivity which means it
is not a good conductor of heat. This results in a higher arc density. Arc density refers to the concentration of
energy in the arc. With argon this energy is confined to a narrow area or "pinpointed" in a small area. With a
given arc length, the arc voltage with argon will be less than with helium. Argon provides excellent arc stabili-
ty and cleaning action even at low amperages. The correct flow rate is an adequate amount to shield the
"molten weld pool area" and protect the tungsten electrode. Any greater flow than this is a waste. The correct
flow rate in cubic feet per hour (CFH) is influenced by many variables that must be considered on each appli-
cation.

HELIUM
The ionization potential of helium is 24.5 volts. Helium has excellent thermal conductivity. The helium arc
column will expand under the heat of the arc reducing the arc density. The arc column is more flared out than
the arc column with argon. The more flared out the arc column the more work surface area is being heated.
The heat at the center of the arc, therefore, can move more readily downward towards the colder metal at the
bottom of the workpiece. This results in a deeper penetrating arc.

Page 19
It was mentioned previously that with an equivalent arc length helium will produce a higher arc voltage than
will argon. Since the total power is a product of voltage and amperage, it is apparent that more heat energy is
available with helium. Helium or argon-helium mixtures are desirable on thick material and where high travel
speeds are desired. The use of 2:1 helium to argon gas mixtures has also been shown to yield lower porosity
welds in production by allowing the use of wider variation in welding parameters. With helium shielding any
slight variation of arc length can have quite an effect on arc voltage and, consequently, total arc power. For
this reason helium is not as desirable as argon for manual operations.
Helium is, therefore, used on applications where the torch is machine guided or held. Deep penetration DCEN
welding of aluminum is done with 2% thoriated tungsten and helium gas shielding. It is also harder to estab-
lish an arc in a helium atmosphere, especially at lower amperages. Argon is exclusively used when welding
below 150 amperes.
Because helium is a light gas, flow rates are usually two or three times that of argon for equivalent shielding.
With the increased flow rate, total cost of shielding goes up sharply. The cost must be weighed against
increased penetration on thick material, and the increased travel speed attainable.

ALUMINUM
PREPARATION OF ALUMINUM FOR WELDING
This requires more consideration than it is often times given. Aluminum is very susceptible to contaminants
which can cause considerable problems when welding. First of all aluminum has a surface oxide which must
be removed. This oxide removal was mentioned briefly when discussing the different current types. There
have been various theories as to how the arc action actually provides the cleaning action. High speed photo-
graphs and films of the arc let us observe the oxide removal.
When the electrode is positive and the work is negative (reverse polarity or during one half of ac cycle) the
positively charged gas ions are attracted to the negative workpiece. These ions strike with sufficient force to
chip away at the brittle oxide much like a miniature sandblasting operation. The electron flow from the work
to the electrode lifts the loosened oxide leaving clean base metal to be welded.
This cleaning action should not be relied upon to do all the cleaning. Mechanical cleaning methods should be
employed to remove heavy oxide, paint, grease, and oil, or any other materials that will hinder proper fusion.
Mechanical cleaning may be done with abrasive wheels, wire brushes, or other mechanical methods. Special
abrasive wheels are available for aluminum and stainless steel wire brushes are recommended. The important
point is that the abrasive wheels and wire brushes should be used only on the material being cleaned. If a wire
brush for example were used on rusty steel, and then on aluminum, the brush can carry contaminants from one
piece to another. The vigorous brushing can impregnate the contaminants carried in the brush into the alu-
minum. The same is true of the abrasive wheel and equipment used to cut and form aluminum.
Another problem sometimes encountered occurs when only the side of the joint being welded is cleaned.
Contamination from the backside or between butting edges can be drawn into the arc area. It is recommended
that both sides of the joint be cleaned if it contains foreign material. Another frequent source of contamination
is the filler metal. Aluminum filler wire and rod oxidizes just like the base metal. If it is severe enough the rod
must be cleaned prior to use. The operator sometimes transfers contaminants from dirty welding gloves onto
the filler rod and consequently into the weld area.

WELDING
Aluminum is a very good conductor of heat. The heat is rapidly conducted away from the arc area and spread
over the workpiece. On small weldments the entire part may heat up to a point that requires reduction of
amperage from the original setting. Remote foot amperage controls are advantageous in these situations. When

Page 20
welding out-of-position the amperage shown may be decreased by about 15%. A water cooled torch is recom-
mended for amperage over 150 or when a smaller profile torch is needed. The electrode stickout beyond the
cup may vary from approximately 1/16" on butt joints to possibly 1/2" in joints where it is difficult to position
the torch. The normal minimum recommended arc length is approximately the same as the electrode diameter.

EWP Alternating
EWZr-1 Current

Gas Ion Electron Al Oxide

Flow Flow

Aluminum

STAINLESS STEEL
"Stainless Steel" is a common term used when referring to chromium alloyed and chromium-nickel alloyed
steels. There are magnetic and non-magnetic types. There are a large number of alloy types and each possess
some specific properties as to corrosion resistance and strength. A check with the manufacturer is recommend-
ed when in doubt about the specific properties of an alloy. Some general characteristics of stainless steels will
be discussed.
The chromium-nickel stainless steels are considered readily weldable. Normally the welding does not adverse-
ly affect the strength or ductility of the deposit, parent metal, or fusion zone. The filler metal used should be of
a compatible, similar composition to the base metal. The heat conductivity of these steels are about 50% that
of mild steels, therefore, the heat is concentrated in the weld area rather than being dissipated throughout the
work. Thermal expansion is usually about 50% greater than mild steel. This increases the tendency for distor-
tion on thin sections.
The weld area should be thoroughly cleaned. Protective paper or plastic coatings are applied to many stainless
sheets. Foreign material may cause porosity in welds and carburation of the surface which will lessen corro-
sion resisting properties. Any wire brushing should be done with stainless stelel wire brushes to prevent iron
pick-up on the stainless steel surfaces. As with other welding procedures, clean dry filler metal should be used,
and proper precautions taken to prevent contamination during welding.
Many job conditions will affect actual amperages, flow rates, filler rod and tungsten types and diameter used.
Some of these job conditions are:
1. Joint Design and Fit-up
2. Job Specifications
3. Use of Backing (Gas, Rings, Bars)
4. Specific Alloy
5. Operator

Metallurgically, heat input can be critical. On many applications it is desired to keep the heat input as low as
possible. In the weld and heat affected zone a metallurgical change takes place known as carbide precipitation.

Page 21
If corrosion resistance is a big factor in service, it will be noticed that some of the corrosion resistance proper-
ties are lost in the weld and adjacent areas that were heated above the temperature where carbide precipitation
occurs (800-1400 F). Keeping heat input to a minimum is necessary in this situation.
The longer the work is at the 800-1200 F temperature, the greater the precipitation. Rapid cooling through
this range will help keep precipitation at a minimum. On some alloys of stainless steel columbium or titanium
are added to prevent carbide precipitation. It is important that the filler metal used is of the same general
analysis as the material being welded.

MILD STEEL
Low carbon steels, commonly referred to as mild steels, are readily welded by the gas tungsten-arc process.
This group of steels is available in many different alloys and types. The familiar structural shapes, plates, and
hot rolled sheet metal are usually of a semi-killed steel. This term means the steel has been partially deoxi-
dized during manufacture, however, it still contains oxygen. When GTAW welding, this oxygen can cause
problems. It will appear in the form of bubbles in the weld puddle, and possibly porosity in the finished weld.
Killed steel has had more of this oxygen removed and presents less of a problem while welding.
A filler wire with sufficient silicon and manganese added as deoxidizers is necessary. Often times the filler
wire is referred to as being double or triple deoxidized(containing titanium, zirconium, and aluminum), such as
ER-70S-2. Lower grade filler rods used for oxyacetylene welding of many hot rolled products are not suitable
for making high quality GTAW welds. Direct current, electrode negative (straight polarity) is recommended
with high frequency start. A touch or scratch start can be used if it does not pose a contamination problem. A
2% thoriated or ceriated tungsten is recommended. A point or taper on the electrode can be used.
The material itself should be mechanically cleaned prior to welding. Rust, paint, oil and grease, or any surface
contaminants should be removed. Hot rolled products such as angle iron, plate and pipe may contain a heavy
mill scale. For best results this should be removed. Black pipe usually contains a varnish-type coating,
which should be removed before welding for best results. All types of alloy steels may also be welded with
this process, if the correct procedure and filler metal are used.
Direction
Of Welding

A. Develop The Pool With Circular Or Side-To-Side Motion

15

15

B. Move Electrode To Trailing Edge Of Pool C. Add Filler Metal To Center Of Leading Edge Of Pool

Keep Rod Keep Rod

In Shield In Shield
Gas Stream Gas Stream

D. Withdraw Rod E. Move Electrode To Leading Edge Of Pool

Technique For Manual Gas Tungsten Arc Welding

Page 22
 GTAW - PULSED
GTAW - Pulsed is the changing of welding current from a high (Peak) amperage to a low (Background)
amperage rapidly and repeatedly. During the cooling time of the low current (Background amperage), the
molten puddle shrinks and partially solidifies. A series of over lapping weld fusion nuggets are formed by the
pulse Peak amperages as the torch moves along the weld axis.
This process is useful whenever welding heat input must be minimized or penetration accurately and repeti-
tively controlled. For out-of-position welding it may prevent weld metal sagging or drop through. Thin materi-
als can be welded with less warpage.

HOW TO SET PULSER CONTROLS:

If the amperage needed for a weld is known for non-pulsed GTAW, the average current for GTAW-Pulsed may
be slightly less than that used for non-pulsed GTAW. As an example, 200 amps is needed for nonpulsed
GTAW, 180 average amps may be used for Pulsed GTAW.
To begin parameter setting, set the Peak amperage required at the welding power source. This limits the pulse
Peak amperage. The Peak amperage should be set at 150% of the average amperage. In this example 1-1/2 x
180 amperes equals 270 amps peak amperage.
NOTE: If used, a foot or torch mounted remote amperage control limits the peak pulse amperage of the power
source.
Set the background amperage to 1/4 of the average current, (1/4 of 180 average amperes equals 45 amps
Background amperage). These two settings will provide pulsing between 270 amps Peak amperage and 45
amps Background amperage.
Wide pulses and narrow cooling times may provide the best results. As a good starting value, set "Per Cent"
(%) on time control at 60%. An increase from this setting will increase the average current, conversely a
decrease in this setting will decrease the average amperage.
Set the Pulse frequency (Pulses-per-second) control to one-pulse-per second as a trial value. A faster torch
travel speed may require a higher pulse frequency. For a given travel speed the pulse frequency should pro-
duce overlapping fusion weld nuggets. An increase from this setting will increase the average current, con-
versely a decrease in this setting will decrease the average amperage.
Amperage has the greatest effect on penetration-increase average amperage to increase penetration.
Establish an arc and adjust the pulse parameters to coordinate torch travel speed and weld nugget fusion over-
lap, penetration etc.
If tungsten melts excessively due to high peak amperages increase the diameter of the tungsten.
NOTE: ALL CONTROLS MAY BE ADJUSTED WHILE WELDING.
.
Qualify procedures and document for future recall.

Page 23
 1 On/Off Switch
1 2 Use switch to turn pulse function
3 4 On and Off.
2 Background Amps
Use Background Amps control to
set the low pulse of the weld am-
perage, which cools the weld
puddle and affects overall heat in-
put. Background Amps is set as a
percentage of peak amperage.
3 Pulse Frequency
(CE Nameplate Only) A range from 0.2510.0 pps
(pulses per second). Control is
1 2 used to determine appearance of
3 4 weld bead.
4 Peak Time
A range of 595% of each pulse
cycle can be spent at the peak
amperage level.
Peak amperage (3400 amps), is
set with the Amperage Adjust-
ment control (see Section A).
5 Peak amperage is the highest
welding amperage allowed to oc-
cur in the pulse cycle. Weld pene-
tration varies directly with peak
amperage.
Percent (%) Peak 5 Pulsed Output Waveforms
Pulsed Output Waveforms
Time Control Setting Example shows affect changing
the Peak Time control has on the
PPS pulsed output waveform.
(50%)
Bkg Amp Application:
Balanced
Peak Amp Pulsing refers to the alternating
raising and lowering of the weld
output at a specific rate. The
raised portions of the weld output
are controlled in width, height,
and frequency, forming pulses of
weld output. These pulses and
More Time the lower amperage level be-
At Peak tween them (called the back-
Amperage (80%) ground amperage) alternately
heat and cool the molten weld
puddle. The combined effect
gives the operator better control
of penetration, bead width,
crowning, undercutting, and heat
More Time At input. Controls can be adjusted
Background while welding.
Amperage
(20%) Pulsing can also be used for filler
material addition technique
training.

Setting A Pulse TIG Welding Condition

Page 24