Operation of GTAW - 7 Steps - Metallurgy (1) - Ocred

1/5/2020 Operation of GTAW:
GTAW:77 Steps | Metallurgy
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Operation of GTAW:
GTAW:77 Steps || Metallurgy
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by : Shrijit G
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The main steps in successful operation of Gas Tungsten Arc Welding (GTAW) include:
(GTAW)include:
1. Electrode Preparation 2. Backing-Up Plates and Purging 3. Arc Initiation 4. Arc
Purging3.
Maintenance 5. Current Rectification with A.C. Welding 6. Welding Technique7.
Technique 7.
Stopping the Arc.
Step # 1. Electrode Preparation:
Preparing the tungsten electrode properly is very important if a strong, clean, and
importantif
quality weld is to be achieved. The symmetry of electrode shape determines the gas
determinesthe
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
currentis is too large the arc
diameteris
wanders from point to point particu larly when DC EN
particularly is used.
ENis
This condition can, however, be corrected by grind ing the electrode to a point. The
grinding
electrode tip angle is related to the welding current and the thickness of the material to
electrodetip
be welded. It ranges between 30° to 120° but the most common angle used
commonangle is 60°. The
usedis
degree of taper also affects the weld penetration; smaller the angle deeper the
degreeof
penetration and narrower the bead.
narrowerthe
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1/17
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process.
The electrode is usually prepared to a balled end with a diameter that must not exceed
1½
11/2 times the diameter
timesthe of the electrode end. Though some
diameterof times the balled end
sometimestheballed is
endis
especially made on an electrode of the shape and size shown
anelectrode in Fig. 9.5 by ini
shownin tially
initially
connecting the electrode in the welding circuit with DCEP and the process is
andtheprocessis
interrupted whena
when a ball of the desired size is produced, but in actual use the electrode
actualuse
end assumes the shape depending upon the type of current and polarity, as is shown in
uponthe
Fig. 9.6. The molten hemispherical tip is most desirable for welding.
9 : r 8 mm
10-13mm aon
Fig. 9-5 Shape and size of wngsten electrode

before making a balled end.
— Tunasten
electrode
. yn Zinmanmat
) bist | maine| |Famei {wer k
Fig. 9-6 Effect of type of current and polarity on the tungsicn electrode up.
Thoriated tungsten electrodes do not ball easily and therefore need nec essarily to be
necessarily
tapered particularly for welding with low currents. They also give more reliable arc
morereliable
initiation
initiation and
and arc
arc stability
stability with
with high welding currents.
high welding Empresa alemana
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Electrode protrusion beyondthe

beyond the gas nozzle is determined bythejoint
by the joint design and
welding position, for example, in downhand welding the electrode may extend upto 5
downhandwelding
mm beyondthe
beyond the nozzle, fillet welds are more
nozzle,fillet difficult to handle from the point of view of
moredifficult
access so an extension of upto 6 mm may be desirable, while for corner welds an
maybedesirable,
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
beyondthe
heated up and in all probability be badly damaged.
andin
Step # 2. Backing-Up Plates and Purging:
After GTAW torch is fitted with the properly prepared tungsten elec
GTAWtorchis trode but before
electrode
starting the welding operation it is essential to set the cleaned up work with adequate
operationit
protection from the backsideto
backside to avoid any ill effect of the atmospheric gases.
anyill
Different methods are used to provide satisfactory backing. One such method
methodsare is the use
methodis
of support bars like the carbon black bar commonly employ
supportbars ed for the same purpose in
employed
oxy-acetylene welding. The second backing method is the introduction of shielding gas
methodis
on the backside.
This is particularly suited to welding of pipes though it can be used

thoughit for a plate-like job
usedfor
by providing a support fixture with backing up gas passing through it, as shown
throughit, in Fig.
shownin
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 backsideit
casethe backside it is
activated, to produce protective gas, when the temperature goes beyonda
beyond a particular
limit.

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G TAW torch
1— Work
Supporting \ Shielding
fixture gas
Fig. 9-7 Setup for shielding gas backing in GTAW.
For complete protection of backside of the weld it is usually purged with gas flow at the
gasflow
back in a manner similar to the one shown
mannersimilar in Fig. 9.7. Gas commonly used for backup
shownin
is inert gas like argon, however, sometimes nitrogen may be used as purging gas for
gasfor
welding stainless steels. Hydrogen may also be used wherethe
mayalso where the explosion problem is
safeguarded against and its absorption by the base metal is not a problem. When it is
Whenit
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
flamesat under--
side safe from the atmosphere and its contaminating effects.
atmosphereand
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
thermionictype,it
electrode tip to start emission of electrons. The ‘touch and draw’ method used for arc
methodusedforarc
initiation in shielded metal arc welding can no doubt be used butit
doubtbe but it results in the
contamination of the tungsten
contaminationof electrode particularly so in the case of high welding
tungstenelectrode
current.
current.
This results in lower ing of the melting point of the electrode tip which can
lowering lead to
canlead
tungsten inclu sion in weld metal, higher consumption
inclusion of electrode and in the
consumptionof
establishment of unstable arc, hence
establishmentof it is an undesirable
henceit practice.
undesirablepractice.
In the light of
of these constraints arc initiation in GTAW is normally done by
constraints
one of
of the following three methods:
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(i) Use of carbon block or scrap material,
(ii)
Gi) High frequency high voltage supply, and
(iii) Low current pilot arc.

currentpilotarc.
It is aacommonpractice
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
arcis
electrode for establishing thermionic emission. This normally takes a few seconds after
secondsafter
which the arc is initiated easily at the spot where welding is to be commenced
thearcis on the
commencedon
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
maythen
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.
aplicacion para
This also re sults in arc wander and increase in
results aprender
arc idiomas
resistance which reduces the current
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density. As these are undesirable conditions it is
conditionsit i often recommended to start the
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5/17
scrap of work material till the required warm up

materialtill of electrode is achieved and then the
upof
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 elec
easyarc trode to the workpiece.
electrode
When the high frequency high voltage current is super
Whenthe imposed over the normal
superimposed
welding circuit it quickly ionises the air gap between the electrode tip and the
weldingcircuit
workpiece thereby making it easy for the electron emission to ensue from the tungsten
makingit
electrode.
The high frequency used ranges between 100 KHz and 2 MHz for a voltage of 3000 to
5000 volts. This method
5000volts. of arc initiation is very efficient and clean and gives a long
methodofarc life
longlife
to the tungsten electrode. Once the arc is initiated and stabilised the HFHV
arcis current is
HFHVcurrentis
switched off and the normal welding circuit comes into operation. Fig. 9.3 shows the
comesinto
electric circuitry for HFHV arc initiation system and Fig 9.8 depicts the basic waveform
HFHVarcinitiation
obtained with such a unit to initiate or sustain the arc.
sot alae] Tee

Voltage(V)
oL LLEAN WY
ai!
Spark gap
wn
oo
oo
o
!
WY volfage wave
Sparks
Fig. 9-8 Basic voltage waveform obtained with high
frequency high voltage unit to initiate or sustain an arc.
Low current pilot arc system is highly reliable arc initiating method which may be used
currentpilot
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
anotherelectrode
nozzle, as shown in Fig. 9.9. The pilot arc is powered by a small auxiliary power source
shownin
and provides conditions for initiat
conditionsfor ing the welding arc in a manner
initiating similar to pilot arc
mannersimilarto
used for lighting gas stove. The pilot arc may
Thepilot either be started by scratch technique or
mayeither
by high frequency energy.
Step # 4. Arc Maintenance:
The maintenance of a stable arc is imperative for getting consistent and good quality
maintenanceof
welds. This may
welds. This may not be much
not be much of
ofaa problem
problem in
inaa Empresa
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voltage and welding current attain zero magnitude
magnit=" every half a cycle. Thus, for a
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normal 50 Hz mains supply the

mainssupply arc goes
thearc off 100
goesoff 10¢ times each second which can Readlead
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arc interruption if adequate measures are not
nottitaken to maintain its stability.
6/17
This is normally done by one of the following three methods:

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

opencircuit
(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

thefirst is so designed
transformeris as to give a suffi
designedasto ciently high OCV
sufficiently
and low electrical inertia to help reignite the arc immedi
lowelectrical ately after the current zero
immediately
pause. During the positive half cycle the electrode runs hotter so there is no need of
Duringthepositive
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
hencethereis
this phenomenon is known
phenomenonis as partial rectification.
knownaspartialrectification.
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
OCVissufficiently
results in a well main tained arc. This method of maintaining a welding
maintained arc is also
weldingarcis
referred to as self re-ignition.
Open- circuit
Circuit Arc voltage
restriking re-ignition ee
voltage voltage
150°
*100F Arc voltage
= * 50 = “0 sitive
= 0 Sri TTPar ie Volt
3 -50F- Arc extinc- O9t EROre

o- 100 a
2 tion
-150* Time —=—
: +200 Positive
<q
= +100 Arc current
. 0
~ 100 Current record
s
:
Neoative
vu —700 Current zero half-cycle
Fig. 9-10 Voltage and currenttransients for a welding transformer with self
reignition method of arc maintenance (After Houldcrofi)
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T/I17
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TECNA models
models 4665
4665 –
— 4668,
4668, 8201
8201 –
— 8214,
8214, 6022
6022 –
— 6023,
6023, 6073
6073 –
—
6075
6075 and
and 6121
6121 –
— 6129
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Self re-ignition though simple has its own drawbacks in that the OCV tends to behigh,
tendsto be high,
which usually approaches 100 volts and
100volts that leads to a low power
andthat factor(i.e., Var¢/OCV).
powerfactor(i.e., Varc/OCV).
For greater reliability self re-ignition is often sup
Forgreaterreliability plemented by providing a high
supplemented
frequency spark unit which is operated from the OCV and becomesinoperative
becomes inoperative when
the voltage drops down to the normal arc operating voltage. This switching
normalarc off also
switchingoff
limits the duration of radio inter ference.
interference.
When HFHV unit is incorporated

HFHVunitis in the welding circuit for continuous
incorporatedin use it can not
continuoususeit
only be used for arc initiation but also for arc maintenance. To accomplish re-ignition
usedforarcinitiation
the sparks are discharged across the arc gap and that provides an ionised path for flow
of current in the main weldingcircuit.
welding circuit. Slightly lower open circuit voltages are required
with high frequency unit and that leads to corresponding improvement in power
improvementin factor.
powerfactor.
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
andit
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.
instantaneousarc
The third method of arc re-ignition involves injecting a voltage surge into the power
methodof
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
powercircuit
moment. If the arc goes off at the end of negative half- cycle, the voltage reignition peak
goesoff
starts developing and that fires a gas dis
andthatfires charge valve which in turn discharges the
dischargevalve
capacitor to re-ignite the arc. Re- ignition in this case is instantaneous and thus
capacitorto
rectificationgempresa
eliminates the possibility of partial rectification alemanaincrea
encountered
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8/17
As the transformer
Asthe docs not have to supply the peak OCV therefore the power
transformerdocs factor of
powerfactor
the system can be improved by utilising a low OCV transformer. The re-ignition infact
improvedbyutilising
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-
oncethearcis
ignited.
The timed voltage surge can only maintain an arc, it cannot initiate it from cold or
cannotinitiate
always after momentary extinction. The circuit diagram for a surge injector
Thecircuit and its
injectorandits
action are depicted in Fig. 9.11.
depictedin
Power
transformer poe Sree 7
'
'
'
'
Switch 7%‘ —Ttorch

Surge
capacitor , ' Work
T
Rrerclhe eintManenareiereariaia eae
Trip unit Step- up
transformer
Applied voltage
surge
Power transformer
=
open-circuit voltage |!
eh
bial,7 NCi
tag
Fig. 9-11 Sarge injector arc maintenance unit and the voltage wave form
obtained with its use (After Houldcrofi).
Step # 5. Current Rectification with A.C. Welding:
Once
Onceaa stable arc is established with a. c. in GTAW the
stablearcis tungsten elec
thetungsten trode gets heated
electrode
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
workpiece. This results
in difference in resistance to current flow which tends to produce unbalanced a. c.
unbalanceda.c.
shown in Fig. 9.12.
shownin

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9/17
. ‘ Small higher current flows

during negative cycles since
= VX Z it is easier for electrons to
« 0 Time flow from the tungsten
i electrode than from the
aa! Large weld pool
This unbalanced waveform + +

can be treatedas two € i
components 3 0 = Time
Balanced Negative
a.c dic.
(a) Equivalence of unbalanced a.c. current.
PEEEEE
oc Voltage but no 0.C . Voltage
* Besitive half cycle are ;
0 | 0 1s
Current 7 Vollage
(b) Current and voltage transients with partial and

full rectification
Fig. 9-12 Principle of current rectification and its representation in the
form of current and voltage transients.
As higher voltage is needed when

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

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

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Transtormer Reactor
, warsRAAAA,
(a ) GTAW circuit with a capacitor
+
WIV Voltage
(b) V-I transients with arc stabilisation
A Capacitor inserted
into the welding circuit
blocks the d.c. component
but allows the balanced
ac. to flow through the arc
0 0
—
Current Voltage
{c) V-] transients with current balancing
Fig. 9-13 Control of inherent rectification.
However, the role of this bank of capacitor is reversed at the time

However,therole of arc initiation when
timeofarc
the arc fails during negative cycle of the current. Thus, it results in inverse rectification
inverserectification
which leaves a charge of reverse polarity to that for which it is inserted in the
whichit circuit.
thecircuit.
Hence, it opposes
Hence,it the arc initiation. To prevent this the suppressing capacitor
opposesthearcinitiation. is
capacitoris
switched out during the period of arc initiation.
periodof
When high frequency

Whenhigh a.c. is used it is easy to initiate the GTAW arc and
frequencya.c. if the HF
andif unit is
HFunitis
used regularly than arc maintenance is also no problem. In such a case
maintenanceis the welding
casethe
transformer is so designed as to keep the tungsten electrode cool and provide necessary
transformeris
heat balance by modifying the positive and negative half cycles as to give the desired
modifyingthe
result. For this purpose
purposeaa positive to a negative half cycle may have a ratio as high as 1:
highas1:
20, and it may beof
andit be of any desired configuration, as shown in Fig. 9.14.
shownin
+
OCRP DCRP to OCSP Ratio

*
- ws can equal 1 to 20
a 0 a a 0 -
S|
.
3
Jin
OCSP
3|
.
3
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Fig. 9-14 Standard and modifie: Read Next Story >
11/17
Step # 6. Welding Technique:
Both manual and mechanised modes of operation are used for GTAW. For manual
modesof
welding, after the arc is initiated, the welding torch
arcis is held at an angle of 70° to 80° in
torchis
the forehand welding position. For mechanised GTAW, the weldingtorchis
GTAW,the welding torch is generally
held perpendicular to the workpiece.
To commence manual
commence welding, the arc is moved in a small circle to create a weld pool
manualwelding,
of suitable size. Once a weld pool of desired size is established at the starting point, a
poolof
weld is made by moving the torch along the weldjoint
movingthe weld joint at the desired welding speed.
Solidification of the molten metal gives the desired weld bead shape and the weld is
achieved.
achieved.
Addition or absence of filler metal in GTAW depends upon the workpiece thickness
absenceoffiller
and the joint design. When filler metal is required to be added during manual
Whenfiller welding,
manualwelding,
it is done by hand feeding the filler rod at the leading end
feedingthefiller of the weld pool.
endof
The welding torch and the filler rod are moved smoothly along the joint edges to
andthefiller
maintain a weld pool of consistent size. It is ensured that the shielding gas blanketis
poolof blanket is
maintained over the molten metal until it is solidified and the hot end of
untilit the filler rod is
ofthefiller
also maintained within the shielding gas envelope to avoid the possibility of oxidation.
Different methods of feeding the

methodsof filler material to the weld pool are adopted. The one
thefiller
most recommended for thin material is that in whichthefiller
recommendedfor 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
andit
shown in Fig. 9.15. In the second method
shownin the filler wire is kept against the workpiece
methodthefiller
along the weld seam and is melted along with joint edge. For large weldthefiller
andis weld the filler wire is
fed continuously into the weld pool; both torch and the filler wire are oscillated but in
andthefiller
the opposite direction. In automatic GTAW the filler wire is fed mechanically through a
GTAWthefiller
guide into the weld pool at a uniform rate.

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12/17
GTAW torch
a Direchon
f weidi
—
Tungsten —
electrode
— 7
(0) Withdraw rod (E) Move torch to leading edge

of puddle
Fig. 9-15 Techniques of feedingfiller rod in GTAW (After AWS-vol. 2, 7th Ed.).
From the point of view of good penetration, proper reinforcement, weld quality and
pointof
economy, downhand or flat welding is best suited for GTAW. However, good
downhandorflat
penetration can also be achieved in vertical up welding. GTAW torch is usually held at
torchis
75° to the workpiece in forehand welding position both for downhand and vertical up
downhandandvertical
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
GTAWis
eliminate the need for filler wire. However, when needed
needforfiller the tiller wire of required size
neededthetiller
is fed into the weld pool from a spool. The mechani sed units often make use
mechanised of arc
useof
length control devices, for which the GTAW torch is clamped on
GTAWtorchis onaa linear actuator and
the movement of the torch along
movementof it is based on the feedback obtained in terms
alongit of
termsof
change in arc voltage.
changein
This device is very useful to keep consistent arc length and thus can easily eliminate the
thuscan
variation in weld geometry due to minor variation in the workpiece contour. However,
minorvariation
it is also employed in automatic GTAW of pipe lines whereit
where it auto matically adjusts the
automatically
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circumferential weld. This ensures that the arc voltage
are Babbel and welding current will remain
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Step # 7. Stopping the Are:

Arc:
The arc needs to be extinguished

Thearc at the end of the weld run and
extinguishedat this needs to be done
andthis
gradually rather than abruptly. Sudden stoppage of welding may lead to defects like
maylead
central pipe and paw cracks. These defects may cause leaks in joints particularly those
causeleaks
intended for use in vacuum or under pressure.
underpressure.
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
graduallytill
also the arc is extinguished by lengthening it which leads to increased voltage and
lengtheningit
reduced current in a manner that depends upon the volt- ampere characteristic of the
uponthe
welding power source.
powersource.
In mechanised welding the end crater is reduced by increasing the welding

welding speed
before switching off. The crater pipe can also be eliminated by re ducing the current
reducing
gradually before stoppage by employing a device called crater
devicecalled filler.
craterfiller.
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
commencesin the torch is
timethetorchis
switched off the flow of current stops immediately but the shielding gas flow is
switchedoff
maintained for a few seconds more to ensure protec
moreto tion of the hot solidifying weld
protection
metal. This is achieved by providing solenoid valvesin
valves in the circuit.
thecircuit.
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Operation of GTAW - 7 Steps - Metallurgy (1) - Ocred

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1/5/2020 Operation of GTAW:

GTAW:77 Steps | Metallurgy

 Your Article Library

Step # 1. Electrode Preparation:

Empresa alemana crea la mejor aplicación

Fig. 9-5 Shape and size of wngsten electrode

Drilling Rig For Sale

Electrode protrusion beyondthe

Step # 2. Backing-Up Plates and Purging:

This is particularly suited to welding of pipes though it can be used

Empresa alemana crea la mejor aplicación

Step # 3. Arc Initiation:

Empresa alemana crea la mejor aplicación

TECNA Press-Type Spot Welders

(i) Use of carbon block or scrap material,

(iii) Low current pilot arc.

scrap of work material till the required warm up

sot alae] Tee

Step # 4. Arc Maintenance:

normal 50 Hz mains supply the

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.

With the first method a transformer

= 0 Sri TTPar ie Volt

3 -50F- Arc extinc- O9t EROre

Empresa alemana crea la mejor aplicación

TECNA Press-Type Spot Welders

When HFHV unit is incorporated

Switch 7%‘ —Ttorch

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

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. ‘ Small higher current flows

This unbalanced waveform + +

(b) Current and voltage transients with partial and

As higher voltage is needed when

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

Empresa alemana crea la mejor aplicación

However, the role of this bank of capacitor is reversed at the time

When high frequency

OCRP DCRP to OCSP Ratio

Fig. 9-14 Standard and modifie: Read Next Story >

Step # 6. Welding Technique:

Different methods of feeding the

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(0) Withdraw rod (E) Move torch to leading edge

consistent with consequential consistency in weld

Step # 7. Stopping the Are:

The arc needs to be extinguished

In mechanised welding the end crater is reduced by increasing the welding

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Import Drill Rig From

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