3.2.

0 Types of Welding CurrentThe type of power source determines the type of

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