Operation of GTAW: 7 Steps - Metallurgy: Tungsten Sheet

1/5/2020 Operation of GTAW: 7 Steps | Metallurgy
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Operation of GTAW: 7 Steps | Metallurgy

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The main steps in successful operation of Gas Tungsten Arc Welding (GTAW) include:
1. Electrode Preparation 2. Backing-Up Plates and Purging 3. Arc Initiation 4. Arc
Maintenance 5. Current Rectification with A.C. Welding 6. Welding Technique 7.
Stopping the Arc.
Step # 1. Electrode Preparation:
Preparing the tungsten electrode properly is very important if a strong, clean, and
quality weld is to be achieved. The symmetry of electrode shape determines the gas
flow pattern and consequently the degree of protection provided to the molten metal in
the weld pool. When the current is loo low or the electrode diameter is too large the arc
wanders from point to point particularly when DC EN is used.
This condition can, however, be corrected by grinding the electrode to a point. The
electrode tip angle is related to the welding current and the thickness of the material to
be welded. It ranges between 30° to 120° but the most common angle used is 60°. The
degree of taper also affects the weld penetration; smaller the angle deeper the
penetration and narrower the bead.
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Tungsten Sheet
The electrode is usually prepared to a balled end with a diameter that must not exceed
1½ times the diameter of the electrode end. Though sometimes the balled end is
especially made on an electrode of the shape and size shown in Fig. 9.5 by initially
connecting the electrode in the welding circuit with DCEP and the process is
interrupted when a ball of the desired size is produced, but in actual use the electrode
end assumes the shape depending upon the type of current and polarity, as is shown in
Fig. 9.6. The molten hemispherical tip is most desirable for welding.
Thoriated tungsten electrodes do not ball easily and therefore need necessarily to be
tapered particularly for welding with low currents. They also give more reliable arc
initiation and arc stability with high welding currents.
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Electrode protrusion beyond the gas nozzle is determined by the joint design and
welding position, for example, in downhand welding the electrode may extend upto 5
mm beyond the nozzle, fillet welds are more difficult to handle from the point of view of
access so an extension of upto 6 mm may be desirable, while for corner welds an
extension of between 1.5 to 3 mm is adequate. The minimum extension of electrode
beyond the nozzle should not be less than 1 .5 mm otherwise the nozzle will get unduly
heated up and in all probability be badly damaged.
Step # 2. Backing-Up Plates and Purging:
After GTAW torch is fitted with the properly prepared tungsten electrode but before
starting the welding operation it is essential to set the cleaned up work with adequate
protection from the backside to avoid any ill effect of the atmospheric gases.
Different methods are used to provide satisfactory backing. One such method is the use
of support bars like the carbon black bar commonly employed for the same purpose in
oxy-acetylene welding. The second backing method is the introduction of shielding gas
on the backside.
This is particularly suited to welding of pipes though it can be used for a plate-like job
by providing a support fixture with backing up gas passing through it, as shown in Fig.
9.7. The use of flux backing is another method of protecting the backside of the weld
from atmospheric contamination. In case the flux is pasted at the backside it is
activated, to produce protective gas, when the temperature goes beyond a particular
limit.

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For complete protection of backside of the weld it is usually purged with gas flow at the
back in a manner similar to the one shown in Fig. 9.7. Gas commonly used for backup
is inert gas like argon, however, sometimes nitrogen may be used as purging gas for
welding stainless steels. Hydrogen may also be used where the explosion problem is
safeguarded against and its absorption by the base metal is not a problem. When it is
not possible to provide a supporting fixture for purging or shielding gas then the
alternative method is to use oxy-hydrogen flames at the backside. This keeps the under-
side safe from the atmosphere and its contaminating effects.
Step # 3. Arc Initiation:
Regular flow of electrons is required for arc initiation to take place. Electron emission
in tungsten being of the thermionic type, it is imperative to raise the temperature of the
electrode tip to start emission of electrons. The ‘touch and draw’ method used for arc
initiation in shielded metal arc welding can no doubt be used but it results in the
contamination of the tungsten electrode particularly so in the case of high welding
current.
This results in lowering of the melting point of the electrode tip which can lead to
tungsten inclusion in weld metal, higher consumption of electrode and in the
establishment of unstable arc, hence it is an undesirable practice.
In the light of these constraints arc initiation in GTAW is normally done by

one of the following three methods:
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(i) Use of carbon block or scrap material,
(ii) High frequency high voltage supply, and
(iii) Low current pilot arc.
It is a common practice to initiate the arc by touch and draw method on a carbon block.
The arc is easily established and is sustained for a short while to warm up the tungsten
electrode for establishing thermionic emission. This normally takes a few seconds after
which the arc is initiated easily at the spot where welding is to be commenced on the
workpiece.
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This method of touch and draw is not always flawless because carbon Particles may
stick to the tungsten electrode which may then be transferred to the workpiece leading
to undesirable inclusion or carbon pick up by the weld metal. The tungsten carbide also
has a lower melting point and, therefore, results in increasing the size of molten
spherical end.
This also results in arc wander and increase in aprender
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density. As these are undesirable conditions it is often recommended to start the arc on
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scrap of work material till the required warm up of electrode is achieved and then the
arc is transferred to the spot where welding is to be commenced.
High voltage high frequency current is often used in conjunction with A.C. power
sources to achieve easy arc initiation without touching the electrode to the workpiece.
When the high frequency high voltage current is superimposed over the normal
welding circuit it quickly ionises the air gap between the electrode tip and the
workpiece thereby making it easy for the electron emission to ensue from the tungsten
electrode.
The high frequency used ranges between 100 KHz and 2 MHz for a voltage of 3000 to
5000 volts. This method of arc initiation is very efficient and clean and gives a long life
to the tungsten electrode. Once the arc is initiated and stabilised the HFHV current is
switched off and the normal welding circuit comes into operation. Fig. 9.3 shows the
electric circuitry for HFHV arc initiation system and Fig 9.8 depicts the basic waveform
obtained with such a unit to initiate or sustain the arc.
Low current pilot arc system is highly reliable arc initiating method which may be used
with a d.c. welding system. The pilot arc is established between the tungsten welding
electrode and another electrode (usually anode) incorporated in the GTAW torch
nozzle, as shown in Fig. 9.9. The pilot arc is powered by a small auxiliary power source
and provides conditions for initiating the welding arc in a manner similar to pilot arc
used for lighting gas stove. The pilot arc may either be started by scratch technique or
by high frequency energy.
Step # 4. Arc Maintenance:
The maintenance of a stable arc is imperative for getting consistent and good quality
welds. This may not be much of a problem in a Empresa
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voltage and welding current attain zero magnitude every half a cycle. Thus, for a
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normal 50 Hz mains supply the arc goes off 100 times each second which can lead
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arc interruption if adequate measures are not taken to maintain its stability.
This is normally done by one of the following three methods:
(i) High open circuit voltage of the welding transformer,
(ii) Imposition of high frequency high voltage on the main welding circuit, and
(iii) Injection of high voltage surge.
With the first method a transformer is so designed as to give a sufficiently high OCV
and low electrical inertia to help reignite the arc immediately after the current zero
pause. During the positive half cycle the electrode runs hotter so there is no need of
high OCV on the negative half cycle as the arc re-ignites immediately on change from
positive to negative half cycle but at negative to positive half cycle change the electrode
is cooler and hence there is delay in re-ignition which results in current zero pause and
this phenomenon is known as partial rectification.
During the current zero pause there is jump in voltage to re-ignite the arc as shown in
Fig. 9.10. Thus, the arc reignites satisfactorily when the OCV is sufficiently high; this
results in a well maintained arc. This method of maintaining a welding arc is also
referred to as self re-ignition.
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Self re-ignition though simple has its own drawbacks in that the OCV tends to be high,
which usually approaches 100 volts and that leads to a low power factor(i.e., Varc/OCV).
For greater reliability self re-ignition is often supplemented by providing a high
frequency spark unit which is operated from the OCV and becomes inoperative when
the voltage drops down to the normal arc operating voltage. This switching off also
limits the duration of radio interference.
When HFHV unit is incorporated in the welding circuit for continuous use it can not
only be used for arc initiation but also for arc maintenance. To accomplish re-ignition
the sparks are discharged across the arc gap and that provides an ionised path for flow
of current in the main welding circuit. Slightly lower open circuit voltages are required
with high frequency unit and that leads to corresponding improvement in power factor.
The high frequency spark unit consists of a capacitor that is charged by high voltage
transformer which discharges through a spark gap. It is so operated that a train of
sparks is generated when the welding power supply voltage exceeds the breakdown
voltage of the spark gap and it is arranged to occur during the period when the welding
current passes through the current zero pause (see Fig 9.8). It usually covers two-thirds
of each half cycle. Due to the cyclic nature of its operation it cannot provide
instantaneous arc re-ignition so results in partial rectification.
The third method of arc re-ignition involves injecting a voltage surge into the power
circuit to supply the peak voltage required for re-ignition. This is achieved by
discharging a capacitor through a switch operated by the power circuit at the intended
moment. If the arc goes off at the end of negative half- cycle, the voltage reignition peak
starts developing and that fires a gas discharge valve which in turn discharges the
capacitor to re-ignite the arc. Re- ignition in this case is instantaneous and thus
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As the transformer docs not have to supply the peak OCV therefore the power factor of
the system can be improved by utilising a low OCV transformer. The re-ignition infact
may be accomplished with 50 volt rms; thus it can also improve the operational safety.
The system works momentarily and is automatically switched out once the arc is re-
ignited.
The timed voltage surge can only maintain an arc, it cannot initiate it from cold or
always after momentary extinction. The circuit diagram for a surge injector and its
action are depicted in Fig. 9.11.
Step # 5. Current Rectification with A.C. Welding:
Once a stable arc is established with a. c. in GTAW the tungsten electrode gets heated
to a much higher temperature than the temperature of the metal being welded. This
results in different abilities of the electrode and the workpiece to emit electrons; the
electrode being hotter emits electrons far more readily than the workpiece. This results
in difference in resistance to current flow which tends to produce unbalanced a. c.
shown in Fig. 9.12.

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As higher voltage is needed when the electrode is positive, it results in lower current
flow which causes partial rectification. This partial rectification is also known as
inherent rectification and results in a d. c component of current which tends to saturate
the transformer resulting in its derating to the extent of 30%. This situation is further
accentuated due to current zero pauses when they occur.
The detrimental effects of inherent rectification can be corrected by inserting banks of

reversible electrolytic capacitors which may give upto 100 pF/A in the power circuit, as
shown in Fig. 9.13. This results in a charge being left on these capacitors when the
electrode is negative which makes more current to flow when the electrode is positive.

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However, the role of this bank of capacitor is reversed at the time of arc initiation when
the arc fails during negative cycle of the current. Thus, it results in inverse rectification
which leaves a charge of reverse polarity to that for which it is inserted in the circuit.
Hence, it opposes the arc initiation. To prevent this the suppressing capacitor is
switched out during the period of arc initiation.
When high frequency a.c. is used it is easy to initiate the GTAW arc and if the HF unit is
used regularly than arc maintenance is also no problem. In such a case the welding
transformer is so designed as to keep the tungsten electrode cool and provide necessary
heat balance by modifying the positive and negative half cycles as to give the desired
result. For this purpose a positive to a negative half cycle may have a ratio as high as 1:
20, and it may be of any desired configuration, as shown in Fig. 9.14.

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Step # 6. Welding Technique:
Both manual and mechanised modes of operation are used for GTAW. For manual
welding, after the arc is initiated, the welding torch is held at an angle of 70° to 80° in
the forehand welding position. For mechanised GTAW, the welding torch is generally
held perpendicular to the workpiece.
To commence manual welding, the arc is moved in a small circle to create a weld pool
of suitable size. Once a weld pool of desired size is established at the starting point, a
weld is made by moving the torch along the weld joint at the desired welding speed.
Solidification of the molten metal gives the desired weld bead shape and the weld is
achieved.
Addition or absence of filler metal in GTAW depends upon the workpiece thickness
and the joint design. When filler metal is required to be added during manual welding,
it is done by hand feeding the filler rod at the leading end of the weld pool.
The welding torch and the filler rod are moved smoothly along the joint edges to
maintain a weld pool of consistent size. It is ensured that the shielding gas blanket is
maintained over the molten metal until it is solidified and the hot end of the filler rod is
also maintained within the shielding gas envelope to avoid the possibility of oxidation.
Different methods of feeding the filler material to the weld pool are adopted. The one
most recommended for thin material is that in which the filler rod is held at 15° to the
workpiece surface ahead of the torch and it is added repeatedly to the weld pool, as
shown in Fig. 9.15. In the second method the filler wire is kept against the workpiece
along the weld seam and is melted along with joint edge. For large weld the filler wire is
fed continuously into the weld pool; both torch and the filler wire are oscillated but in
the opposite direction. In automatic GTAW the filler wire is fed mechanically through a
guide into the weld pool at a uniform rate.

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From the point of view of good penetration, proper reinforcement, weld quality and
economy, downhand or flat welding is best suited for GTAW. However, good
penetration can also be achieved in vertical up welding. GTAW torch is usually held at
75° to the workpiece in forehand welding position both for downhand and vertical up
welding. Vertical down welding is usually not satisfactory; metal may droop, and lack of
penetration often results.
Mechanised GTAW is frequently employed and often the joints are so designed as to
eliminate the need for filler wire. However, when needed the tiller wire of required size
is fed into the weld pool from a spool. The mechanised units often make use of arc
length control devices, for which the GTAW torch is clamped on a linear actuator and
the movement of the torch along it is based on the feedback obtained in terms of
change in arc voltage.
This device is very useful to keep consistent arc length and thus can easily eliminate the
variation in weld geometry due to minor variation in the workpiece contour. However,
it is also employed in automatic GTAW of pipe lines where it automatically adjusts the
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Step # 7. Stopping the Arc:
The arc needs to be extinguished at the end of the weld run and this needs to be done
gradually rather than abruptly. Sudden stoppage of welding may lead to defects like
central pipe and paw cracks. These defects may cause leaks in joints particularly those
intended for use in vacuum or under pressure.
The normal method of stopping the arc, therefore, is by reducing the welding speed and
withdrawing the torch gradually till the crater is completely filled up. In d.c. welding
also the arc is extinguished by lengthening it which leads to increased voltage and
reduced current in a manner that depends upon the volt- ampere characteristic of the
welding power source.
In mechanised welding the end crater is reduced by increasing the welding speed
before switching off. The crater pipe can also be eliminated by reducing the current
gradually before stoppage by employing a device called crater filler.
In all these cases the welding circuit is so designed as to switch on the shielding gas
before the flow of current commences in the welding circuit and at the time the torch is
switched off the flow of current stops immediately but the shielding gas flow is
maintained for a few seconds more to ensure protection of the hot solidifying weld
metal. This is achieved by providing solenoid valves in the circuit.
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Operation of GTAW: 7 Steps - Metallurgy: Tungsten Sheet

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1/5/2020 Operation of GTAW: 7 Steps | Metallurgy

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Operation of GTAW: 7 Steps | Metallurgy

Step # 1. Electrode Preparation:

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Step # 2. Backing-Up Plates and Purging:

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Step # 3. Arc Initiation:

In the light of these constraints arc initiation in GTAW is normally done by

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TECNA Press-Type Spot Welders

(i) Use of carbon block or scrap material,

(ii) High frequency high voltage supply, and

(iii) Low current pilot arc.

Step # 4. Arc Maintenance:

This is normally done by one of the following three methods:

(i) High open circuit voltage of the welding transformer,

(iii) Injection of high voltage surge.

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TECNA Press-Type Spot Welders

Step # 5. Current Rectification with A.C. Welding:

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The detrimental effects of inherent rectification can be corrected by inserting banks of

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Step # 6. Welding Technique:

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consistent with consequential consistency in weld quality. Read Next Story

Step # 7. Stopping the Arc:

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