This does not cover all phases of welding, but briefly presents the basic

facts of the TIG welding process and techniques.

LIST OF CONTENTS Page No

History of TIG 2


TIG Overview 3

Power Sources 4

Types of Welding Current used for TIG 5

Characteristics of Current Types for Gas Tungsten Arc Welding 7

TIG Handpiece (TIG Torch) 9

Selecting the Correct Torch Nozzle 10

Gas Lens Benefits 10

Regulators 11

Connection Diagrams 12

Tungsten Selection and Preparation 13

Tungsten Colour Code and Proper Torch Use 14

TIG Wires 15

Shielding Gas 16

Shield Gas Selection and Use 17

Typical Manual GTA (TIG Welding Parameters) 18

Guide for Shield Gas Flows, Current Settings and Cup Selection 20

Correct Torch and Rod Positioning 20

Pulsed TIG 21

Personal Protection 22

Recognising Your Tungsten 23

Operator Inspection for Weld Quality 24

TIG Troubleshooting Guide 25

1
 HISTORY OF GTAW (TIG WELDING)
TIG welding was, like MIG/MAG developed during 1940 at the start of the
Second World War.

TIG’s development came about to help in the welding of difficult types of

material, eg aluminium and magnesium. The use of TIG today has spread to
a variety of metals like stainless mild and high tensile steels.

GTAW is most commonly called TIG (Tungsten Inert Gas).

The development of TIG welding has added a lot in the ability to make
products, that before the 1940’s were only thought of.

Like other forms of welding, TIG power sources have, over the years, gone
from basic transformer types to the highly electronic power source of the
world today.

2
OVERVIEW
TIG welding is a welding process that uses a power source, a shielding gas
and a TIG handpiece. The power is fed out of the power source, down the
TIG handpiece and is delivered to a tungsten electrode which is fitted into the
handpiece. An electric arc is then created between the tungsten electrode
and the workpiece. The tungsten and the welding zone is protected from
the surrounding air by a gas shield (inert gas). The electric arc can produce
temperatures of up to 19,400oC and this heat can be very focused local
heat.

The weldpool can be used to join the base metal with or without filler
material.

The TIG process has the advantages of -

1) Narrow concentrated arc
2) Able to weld ferrous and non-ferrous metals
3) Does not use flux or leave a slag
4) Uses a shielding gas to protect the weldpool and tungsten
5) A TIG weld should have no spatter
6) TIG produces no fumes but can produce ozone

The TIG process is a highly controllable process that leaves a clean weld
which usually needs little or no finishing. TIG welding can be used for both
manual and automatic operations.

The TIG welding process is so good that it is wisely used in the so-called
high-tech industry applications such as
1) Nuclear industry
2) Aircraft
3) Food industry
4) Maintenance and repair work
5) Some manufacturing areas

3
 POWER SOURCES
TIG welding power sources have come a long way from the basic transformer
types of power sources which were used with add-on units to enable the
power source to be used as a TIG unit, eg high frequency unit and/or DC
rectifying units,
The basics of TIG welding has almost remained the same, but the advent of
technology TIG welding power sources have made the TIG processes more
controllable and more portable in some cases.

The TIG power source uses main power connected to a suitable power for
the TIG process being used. This can be either AC or DC.

The one thing that all TIGs have in common is that they are CC (Constant
Current) type power sources. This means only output adjustment will control
the power source amps. The voltage will be up or down depending on the
resistance of the welding arc.

A TIG power source can be of the AC or DC type. The principle of electric

circuits will apply to only DC power sources. This means 70% of the heat is
always on the positive side. So when a DC power source is used whatever
is connected to the positive side will have 70% of the energy output (heat).
When using an AC power source, which has an output of a wave form, the
average on both terminals will be the same. This is because for one half
of the wave form (cycle) the positive terminal will have 70% of the energy,
but as the wave form moves to the other half of the cycle it will move to the
negative terminal, which will then have the 70% of the energy.

Other things to check on TIG power sources are -

1) Amperage to do the job. Will it be sufficient?
2) Does the amperage go low enough for light material and high enough
for thick material?
3) Power Supply - 400 Volt, 230 Volt - single or three phase. Is there
enough main power to do the job?
4) Is weight a problem? If so, is the inverter type power source more
suitable.
5) Will an engine driven power source be better to do the job? (Must
have CC range). Might need suitable extra add-ons to do the eg, HF
unit.
6) Would a multi-process type power source be better to do the job?
Must have CC range.
7) Does the TIG welding need an AC power source or DC power source,
as different material will need a different power type.

4
TYPES OF WELDING CURRENT USED FOR TIG
1) DCSP - Direct Current Straight Polarity - (the tungsten electrode is
connected to the negative terminal). This type of connection is the
most widely used in the DC type welding current connections. With the
tungsten being connected to the negative terminal it will only receive
30% of the welding energy (heat). This means the tungsten will run a lot
cooler than DCRP. The resulting weld will have good penetration and a
narrow profile.

2) DCRP - Direct Current Reverse Polarity - (the tungsten electrode is

connected to the positive terminal). This type of connection is used
very rarely because most heat is on the tungsten, thus the tungsten can
easily overheat and burn away. DCRP produces a shallow, wide profile
and is mainly used on very light material at low amps.

3) AC - Alternating Current is the preferred welding current for most white
metals, eg aluminium and magnesium. The heat input to the tungsten is
averaged out as the AC wave passes from one side of the wave to the
other.

On the half cycle, where the tungsten is positive electron welding current
will flow from base material to the tungsten. This will result in the lifting
of any oxide skin on the base material. This side of the wave form is
called the cleaning half. As the wave moves to the point where the
tungsten becomes negative the electrons (welding current) will flow from
the welding tungsten to the base material. This side of the cycle is
called the penetration half of the AC wave form.
 Because the AC cycle passes through a zero point the arc goes out.
This can be seen with fast film photography. At this point the arc would
stay out if it wasn’t for the introduction of HF (high frequency). High
frequency has very little to do with the welding process; its job is the
re-ignition of the welding current as it passes through zero. (How good
the HF is will often have a bearing on how well the re-ignition of the arc
is.) HF is also often used for starting the welding arc initially without
the tungsten touching the workpiece. This helps on materials that are
sensitive to impurities. HF start can also be used on DC welding current
to initially start the welding current without the tungsten touching the
workpiece.
It is a common misunderstanding that the HF does the cleaning action.
This is not the case, it only serves to re-ignite the welding arc.

5
 4) AC - Alternating Current - Square Wave

With the advent of modern electricity AC welding

machines can now be produced with a wave form called +
Square Wave. The square wave has the benefit of a
lot more control and each side of the wave can be, in
some cases, controlled to give a more cleaning half of -
the welding cycle, or more penetration.
Once the welding current gets above a certain amperage (often depends on
the machine) the HF can be turned off, allowing the welding to be carried on
with the HF interfering with anything in the surrounding area.

6
CHARACTERISTICS OF CURRENT TYPES FOR
GAS TUNGSTEN ARC WELDING
When TIG welding, there are three choices of welding current. They
are: Direct Current Straight Polarity, Direct Current Reverse Polarity, and
Alternating Current with High Frequency stabilisation. Each of these has its
applications, advantages, 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. The diagrams below, show arc characteristics of
each current polarity type.

CURRENT TYPE DCSP DC TIG

POWER
Electrode Polarity Electrode Negative SUPPLY

Oxide Cleaning Action No

70% at work end
Heat Balance in the Arc
30% at electrode end
Penetration Profile Deep, narrow
Electrode Capacity Excellent

TIG welding with DCSP (direct current straight polarity) produces deep
penetration because it concentrates the heat in the joint area. No cleaning
action occurs with this polarity.

DC TIG
POWER CURRENT TYPE DCRP
SUPPLY
Electrode Polarity Electrode Positive
Oxide Cleaning Action Yes
30% at work end
Heat Balance in the Arc
70% at electrode end
Penetration Profile Shallow, wide
Electrode Capacity Poor

TIG welding with DCRP (direct current reverse polarity) produces good
cleaning action as the argon ions flowing towards the work strike with
sufficient force to break up oxides on the surface.

7
 AC TIG
POWER CURRENT TYPE ACHF
SUPPLY
Electrode Polarity Alternating
Oxide Cleaning Action Yes (once every half cycle)
50% at work end
Heat Balance in the Arc
50% at electrode end
Penetration Profile Medium
Electrode Capacity Good

8
TIG HANDPIECE (TIG TORCH)
The function of the TIG handpiece is to
1) hold the electrode tungsten
2 deliver welding current to the tungsten via a welding power cable
3) deliver shielding gas to the TIG torch nozzle. The nozzle then directs
the shielding gas to cover the weldpool protecting it from contamination
from the surrounding air.
4) often will be the way of getting the welder control circuit to the operation,
eg on/off and/or amperage control.
5) the TIG handpiece can be watercooled. Hoses in the TIG lead will
supply cooling water to the TIG torch head assembly.
6) the TIG torch length will allow a distance from the TIG power source
and workpiece.
TIG torches come in different styles depending on the brand being selected.
But they all have things in common -
1) aircooled or watercooled
2) current rating. The operator must select the correct amperage rating
TIG torch.
Using a TIG torch that is not sufficiently rated for the machine may result
in the TIG torch overheating. A TIG torch wiith an excessive rating may be
larger and heavier than a lower amperage TIG torch.

The TIG torch is made up of

1) Leads - The lead will be set up for either aircooled or watercooled. It
will be at a length suitable to do the job, eg 4 metre, 8 metre, etc. The
lead will be made up of a power cable, gas hose and water leads in
and out if the TIG torch is watercooled. The lead may also include a
control lead.
2) Tungsten Holders - Holders may vary with different brands of TIG
torches.
3) Nozzles - The nozzle’s job is to direct the correct gas flow over the
weldpool. (Please see Selecting the Correct Torch Nozzle, page 10.)
4) Back Caps - The back cap is the storage area for excess tungsten.
They can come in different lengths depending on the space the torch
may have to get into (eg. long, medium and short caps).
Please make sure when ordering a TIG torch to tell the supplier the amperage
rating, whether water- or air-cooled, and the fitting that is to go on the end of
the TIG torch lead suitable to fit the TIG power source it will be used from.
This may include power cable fit up, gas fittings and control plug fittings.

9
 SELECTING THE CORRECT TORCH NOZZLE

Design diameter The exit diameter (diameter closest to the arc) is

to fit manufactured in a variety of sizes. GTAW nozzles
GTAW torch are also made in various lengths from short nozzles
to extra-long nozzles.
Alumina nozzles, are the most commonly used
nozzles in GTAW. Alumina nozzles are moulded
from alumina oxide and the density of the alumina
oxide determines the quality of the nozzle in
relationship to impact resistance and thermal sock.
Alumina nozzles are more impact resistant than
lava nozzles. The impact resistance of the alumina
nozzles makes them more durable and are used
for general applications.
The exit diameter for any nozzle is specified with
a number that represents the diameter in 1.6 mm
increments. A number 5 nozzle is therefore 8 mm
diameter. A number 6 nozzle is 9.6 mm and so
on.
Exit
diameter The diameter for any nozzle must be large enough
measured to allow the entire weld area to be covered by the
in 1.6 mm
shielding gas. The exist diameter can be neither
too large nor too small, or poor shield gas coverage
will result. (Refer to page ? for correct cup size.)

GAS LENS BENEFITS

A collet body with a gas lens can be
very useful to a welder. The purpose
of a gas lens is to make the shielding
gas exist the nozzle as a column
instead of as a turbulent stream of
gas that begins to spread out after
exiting. The column of gas allows
the electrode to stick out farther for
visibility, allowing for better access to
the weld area, and a reduction in gas
flow (CFH/L/Min.)

10
REGULATORS
The function of the gas regulator is to reduce bottle pressure gas down to
a lower pressure and deliver it at a constant flow. This constant flow of gas
flows down through the TIG torch lead to the TIG torch nozzle and around
the weldpool.
There are three main styles of regulator used for TIG
One made up with a single flow tube assembly (Fig. 1).
Another made up with a twin-flow tubes assembly (Fig. 3) (this set-up is
excellent for when purging is necessary).
The third style does not have a flow tube and the flow is set by turning
a handwheel (Fig. 2). The amount of gas flow needed to do the job will
depend on the welding job being done and the type of material being
welded. But a common setting to start with is 5 L/min.

Fig. 3
Fig. 1

Fig. 2

11
 CONNECTION DIAGRAMS

2 piece Cable Assembly

FOR GAS COOLED
TORCHES
Power
Source
Shield
gas
supply

FOR WATER COOLED

TORCHES

TIG Regulator-
Torch Flowmeter
Power Source
Power cable
Water adaptor Coolant
out required Recirculator Shield
gas
supply
WATER IN
ARGON IN

Note: 1 litre per minute flow rate. Water in through water line. Water out
through power cable.

12
TUNGSTEN SELECTION AND PREPARATION

Base Metal Thickness Desired Welding Tungsten Performance

Electrode Type Shield Gas
Type Range Results Current Characteristics
Balls easily, low cost, tends to spit at
Pure (EW-P) Argon higher currents, used for non-critical
welds only.
Balls well, takes higher current, with
General Zirconiated
All AC/HF Argon less spitting and with better arc starts
Purpose (EW-Zr)
and arc stability than pure tungsten.
Aluminium Higher current range and stability,
2% Thoriated 75 Argon
better arc starts, with lower tendency
Alloys and (EW-Th2) 25 Helium
to spit, medium erosion.
Lowest erosion rate, widest current
Magnesium Only thin Control 2% Ceriated Argon
DCRP range, AC or DC, no spitting, best arc
sections penetration (EW-Ce2) Helium
Alloys starts and stability.
Best stability at medium currents,
2% Thoriated 75 Argon
Increase good arc starts, medium tendency to
Only (EW-Th2) 25 Helium
penetration spit, medium erosion rate.
thick DCSP
or travel Low erosion rate, wide current range,
sections 2% Ceriated
speed Helium AC or DC, no spitting, consistent arc
(EW-Ce2)
starts, good stability.
Best stability at medium currents,
2% Thoriated 75 Argon
good arc starts, medium tendency to
Copper (EW-Th2) 25 Helium
General spit, medium erosion rate.
All DCSP
Alloys, Purpose Low erosion rate, wide current range,
2% Ceriated 75 Argon
AC or DC, no spitting, consistent arc
(EW-Ce2) 25 Helium
Cu-Ni starts, good stability.
Use on lower currents only, spitting
Only thin Control Zirconiated
Alloys ACHF Argon on starts, rapid erosion rates at higher
sections penetration (EW-Zr)
currents.
and Nickel
Increase Low erosion rate, wide current range,
Only 2% Ceriated 75 Argon
penetration
Alloys thick DCSP AC or DC, no spitting, consistent arc
or travel (EW-Ce2) 25 Helium
sections starts, good stability.
speed
Best stability at medium currents,
2% Thoriated 75 Argon
good arc starts, medium tendency to
(EW-Th2) 25 Helium
Mild spit, medium erosion rate.
Low erosion rate, wide current range,
General 2% Ceriated 75 Argon
Steels, All DCSP AC or DC, no spitting, consistent arc
Purpose (EW-Ce2) 25 Helium
starts, good stability.
Carbon Lowest erosion rate, wide current
2% Lanthanated 75 Argon
range on DC, no spitting, best DC arc
Steels, (EWG-La2) 25 Helium
starts and stability.
Use on lower currents only, spitting
Alloy Only thin Control Zirconiated
ACHF Argon on starts, rapid erosion rates at higher
sections penetration (EW-Zr)
Steels and currents.
Low erosion rate, wide current range,
2% Ceriated 75 Argon
Titanium Increase no spitting, consistent arc starts, good
Only (EW-Ce2) 25 Helium
penetration stability.
thick DCSP
Alloys or travel Lowest erosion rate, highest current
sections 2% Lanthanated
speed Helium range, no spitting, best DC arc starts
(EWG-La2)
and stability.
13
 TUNGSTEN COLOUR CODE AND PROPER TORCH
USE

COLOUR CODE AND ALLOYING ELEMENTS FOR VARIOUS TUNGSTEN

ELECTRODE ALLOYS

AWS Alloying Alloying Nominal Weight of

Colour*
Classifications Element Oxide 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 Grey Not Specified** - -

* Colour may be applied in the form of bands, dots, etc, at any point on the surface of the
electrode.
** Manufacturers must identify the type and nominal content of the rare earth oxide additions.

TUNGSTEN TIP TUNGSTEN EXTENSION

PREPARATION Standard Parts
DCSP (EN) or DCRP (EP)
Flat: 1/4 to General
1/2 x dia Purpose
2-3 dia 3 x dia.
Taper Length
ACHF
General Purpose
Max.
ball
1 x dia
Ball tip by arcing on clean metal at
low current DCRP (EP) then slowly
increase current to form the desired
ball diameter. Return setting to AC.

TUNGSTEN GRINDING

Shape by grinding longitudinally (never radially). Remove the sharp point

to leave a truncated point with a flat spot. Diameter of flat spot determines
amperage capacity. (See below.)

The included angle determines weld bead shape and size. Generally, as the
included angle increases, penetration increases and bead width decreases.

Use a medium (60 grit or finer) aluminium oxide wheel.

14
TIG WIRES
The selection of the TIG wire to be used in the TIG process is a decision
that will depend on
1) The composition of the material being welded
2) Mechanical properties of the weld material and those that are a
match for the base material
3) Corrosion resistance should match
4) Joint design
5) Thickness of the base material
6) Cost

15
 SHIELDING GAS
Like other welding processes the job of the shielding gas is to protect the
weld pool from contamination from air, which can cause porosity and defects
in the weld. The shielding gas is a pathway for the welding arc and will help
in the starting and running of the welding arc.
In New Zealand the most common gas being used for TIG welding is Argon
gas.
Overseas Helium is also being used and in days gone by in some countries
the weld process was called Heliarc welding.
Each of these two gases has advantages.

Argon
1) Better arc starting
2) Good cleaning action
3) Lower arc voltage
4) Low gas flows needed

Helium
1) Faster travel
2) Better penetration
3) Higher arc voltages
Because of the cost of Helium we are now seeing mixtures of Argon and
Helium. This is to gain the best part of each gas. Please see your local gas

16
SHIELD GAS SELECTION AND USE

Base Metal Thickness Weld Shield Characteristics

Type Range Type Gas Type
Best arc starts, control of penetration,
Thin Manual Pure Argon cleaning and appearance on thin
gauges.
Increase heat input with good arc
Aluminium Thick Manual 75 Ar - 25 He starts of argon, but with faster welding
speeds.
Alloys and General Best overall for good arc starts,
Manual Pure Argon control of penetration, cleaning and
Purpose appearance.
Magnesium
Higher weld speed under 20mm thick,
Alloys Thin Mechanised 50 Ar - 50 He with good arc stability and starting.
Highest weld speeds, deeper
penetration with DCSP, demanding
Thick Mechanised Pure Helium arc starting and fixturing requirements,
high flow rates needed.
Good control of weld puddle, bead
Thin Manual Pure Argon contour, and penetration on thin
gauges.
Copper Increase heat input with good arc
Thick Manual 75 Ar - 25 He starts of argon, but with faster welding
speeds.
Alloys
Increase heat input with good arc
General
Cu-Ni Alloys Manual 75 Ar - 25 He starts of argon, but with faster welding
Purpose speeds.
Nickel Higher weld speed under 20mm thick,
Thin Mechanised 25 Ar - 75 He with good arc stability and starting.
Alloys
Highest weld speeds, deeper
penetration with DCSP, demanding
Thick Mechanised Pure Helium arc starting and fixturing requirements,
high flow rates needed.
Best arc starts, control of penetration,
Thin Manual Pure Argon cleaning and appearance on thin
gauges.
Increase heat input with good arc
Low Carbon Thick Manual 75 Ar - 25 He starts of argon, but with faster welding
speeds.
Alloys and Best overall for good arc starts,
General Manual Pure Argon control of penetration, cleaning and
Purpose
Low Alloy appearance.
Best overall for good arc starts,
Steels Thin Mechanised Pure Argon control of penetration, cleaning and
appearance.
Increase heat input with good arc
Thick Mechanised 75 Ar 25 He starts of argon, but with faster welding
speeds.

17
 TYPICAL MANUAL GTA (TIG) WELDING PARAMETERS
ALUMINIUM (ACHF)

Filler Shield Gas Flow

Metal Joint Tungsten Cup Welding Travel
Rod CFH
Gauge Type size Size Type PSI Amperes Speed
Size (L/Min)
Butt 60-80 307 mm
1.6 mm 1.6 mm 1.6 mm 4, 5, 6 Argon 15 (7) 20
Fillet 70-90 256 mm
Butt 2.4 mm 125-145 307 mm
3.2 mm 2.4 mm 6, 7 Argon 17 (8) 20
Fillet 3.2 mm 140-160 256 mm
Butt Argon/ 190-220 258 mm
4.8 mm 3.2 mm 3.2 mm 7, 8 21 (10) 20
Fillet Helium 210-240 230 mm
Butt Argon/ 260-300 256 mm
6.4 mm 4.8 mm 3.2 mm 8, 10 25 (12) 20
Fillet Helium 280-320 205 mm

WELDING ALUMINIUM
The use of TIG welding for aluminium has many advantages for both manual and automatic
processes. Filler metal can be either wire or rod and should be compatible with the base alloy.
Filler metal must be dry, free of oxides, grease, or other foreign matter. If filler metal becomes
damp, heat for 2 hours at 120oC before using. Although ACHF is recommended, DCRP has
been successful up to 2.4mm, DCSP with helium shield gas is successful in mechanised
applications.

MAGNESIUM (ACHF)

Filler Shield Gas Flow

Metal Joint Tungsten Cup Welding Travel
Rod CFH
Gauge Type size Size Type PSI Amperes Speed
Size (L/Min)
Butt 2.4 mm 60
1.6 mm 1.6 mm 5, 6 Argon 13 (5) 15 512 mm
Fillet 3.2 mm 60
Butt 3.2 mm 115
3.2 mm 2.4 mm 7, 8 Argon 19 (9) 15 435 mm
Fillet 4.0 mm 115
Butt 100-130 563 mm
6.4 mm 4.8mm 4.0 mm 8 Argon 25 (12) 15
Butt(2) 110-135 512 mm
12.8 mm Butt(2) 6.4 mm 4.8 mm 10 Argon 35 (17) 15 260 256 mm

WELDING MAGNESIUM
Magnesium alloys are in three groups, they are (1) aluminium-zinc-magnesium, (2) aluminium-
magnesium, and (3) maganese-magnesium. Since magnesium absorbs a number of harmful
ingredients and oxidize rapidly when subjected to welding heat, TIG welding in an inert
gas atmosphere is distinctly advantageous, the welding of magnesium is similar, in many
respects, to the welding of aluminium. Magnesium was one of the first metals to be welded
commercially by TIG. Magnesium requires a positive pressure of argon as a backup on the
root side of the weld.

18
STAINLESS STEEL (DCSP)

Filler Shield Gas Flow

Metal Joint Tungsten Cup Welding Travel
Rod CFH
Gauge Type size Size Type PSI Amperes Speed
Size (L/Min)
Butt 80-100 307mm
1.6 mm 1.6 mm 1.6 mm 4, 5, 6 Argon 11 (5.5) 20
Fillet 90-100 256 mm
Butt 120-140 307 mm
3.2 mm 1.6 mm 2.4 mm 4, 5, 6 Argon 11 (5.5) 20
Fillet 130-150 256 mm
Butt 2.4 mm 200-250 307 mm
4.8 mm 2.4 mm 3.2 mm 5, 6, 7 Argon 13 (6) 20
Fillet 225-275 256 mm
3.2 mm
Butt 275-350 256 mm
6.4 mm 3.2 mm 4.8 mm 8, 10 Argon 13 (6) 20
Fillet 300-375 205 mm

WELDING STAINLESS STEEL

In TIG welding of stainless steel, welding rods having the AWS-ASTM prefixes of E or ER can
be used as filler rods. However, only bare uncoated rods should be used. Stainless steel can
be welded using ACHF, however, recommendations for DCSP must be increased 25%. Light
gauge metals less than 1.6 mm thick should always be welded with DCSP using argon gas.
Follow the normal precautions for welding stainless such as: Clean surfaces; dry electrodes;
use only stainless steel tools and brushes, carefully remove soap from welds after pressure
testing; keep stainless from coming in contact with other metals.

LOW ALLOY STEEL (DCSP)

Filler Shield Gas Flow

Metal Joint Tungsten Cup Welding Travel
Rod CFH
Gauge Type size Size Type PSI Amperes Speed
Size (L/Min)
Butt 95-135 384 mm
1.6 mm 1.6 mm 1.6 mm 4, 5, 6 Argon 15 (7) 20
Fillet 95-135 384 mm
Butt 1.6 mm 145-205 282 mm
3.2 mm 2.4 mm 4, 5, 6 Argon 15 (7) 20
Fillet 2.4 mm 145-205 282 mm
Butt 210-260 256 mm
4.8 mm 2.4 mm 3.2 mm 7, 8 Argon 16 (6.5) 20
Fillet 210-260 256 mm
Butt 240-300 256 mm
6.4 mm 3.2 mm 4.0 mm 8, 10 Argon 18 (8.5) 20
Fillet (2) 240-300 256 mm

WELDING LOW ALLOY STEEL

Mild and low carbon steels with less than 0.30% carbon and less than 25 mm thick, generally
do not require preheat. An exception to this allowance is welding on highly restrained joints.
These joints should be preheated 10 to 38oC to minimise shrinkage cracks in the base metal.
Low alloy steels such as the chromium-molybdenum steels will have hard heat affected zones
after welding, if the preheat temperature is too low. This is caused by rapid cooling of the base
material and the formation of martensitic grain structures. A 90 to 200oC preheat temperature
will slow the cooling rate and prevent the martensitic structure.
19
GUIDE FOR SHIELD GAS FLOWS, CURRENT
SETTINGS AND CUP SELECTION

Welding Current Argon Flow Argon Flow

(Amps) - Ferrous Metals - Aluminium
Electrode - Tungsten Type
Cup
Diameter Size
(mm) AC DCSP Standard Gas Lens Standard Gas Lens
Zirconiated Thoriated Body Body Body Body
CFH (L/min) CFH (L/min) CFH (L/min) CFH (L/min)
0.50 3, 4 or 5 5 - 20 5 - 20 5-8 (3-4) 5-8 (3-4) 5-8 (3-4) 5-8 (3-4)
1.00 4 or 5 15 - 80 20 - 80 5-10 (3-5) 5-8 (3-4) 5-12 (3-6) 5-10 (3-5)
1.60 4, 5 or 6 70 - 150 50 - 150 7-12 (4-6) 5-10 (3-5) 8-15 (4-7) 7-12 (4-6)
2.40 6, 7 or 8 140 - 235 135 - 235 10-15 (5-7) 8-10 (4-5) 10-20 (5-10) 10-15 (5-7)
3.20 7, 8 or 10 220 - 325 240 - 350 10-18 (5-9) 8-12 (4-6) 12-25 (6-12) 10-20 (5-10)
4.00 8 or 10 300 - 425 350 - 500 15-27 (7-12) 10-15 (5-7) 15-30 (7-14) 12-25 (6-12)
4.80 8 or 10 400 - 525 475 - 800 20-35 (10-17) 12-25 (6-12) 25-40 (12-19) 15-30 (7-14)
6.40 10 500 - 700 700 - 1100 25-50 (12-24) 20-35 (10-17) 30-55 (14-26) 25-45 (12-21)

CORRECT TORCH AND ROD POSITIONING

Vertical

Tungsten Electrode

Welding Rod

60o - 75o
Shield Gas
Nozzle

15o - 30o

Direction of Travel

The suggested electrode and welding rod angles for welding a bead on
plate. The same angles are used when making a butt weld. The torch is
held 60o  - 75o from the metal surface. This is the same as holding the torch
15o - 30o from the vertical.
Take special note that the rod is in the shielding gas during the welding
process.

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PULSED TIG
Pulsed TIG has the advantages of
1) better penetration with less heat
2) less distortion
3) better control when welding out of position
4) Easy to use on thin materials
The down side is - more set-up cost and more operator training.

Pulsed TIG consists of

Peak Current - This is set up higher than for non-pulsed TIG.
Background Current - This is set lower than peak current and is the bottom
current the pulse will drop to, but must be enough to keep the arc alive.
Pulses Per Second - This is the number of times per second that weld
current reaches peak current.
% on Time - This is the pulse peak duration as a percentage of the total
time, which controls how long the peak current is on for before dropping to
the background current.

Down Slope - This is the way and the time taken for the welding current
to wind down at the end of the TIG weld. Down slope will help prevent the
uneven cooling of the final weld pool and will help stop pinholes forming at
the completion of a TIG weld.
Post Flow - Post flow is the time taken for the shielding gas to stay on after
the welding current has stopped. This time will
1) protect the end of the weld
2) protect the cooling down of the tungsten (the oxidation of the
tungsten).
Pre-Flow - Preflow is used at the start of the welding process to help protect
the start of the weld from contamination and to make sure the shielding gas
is flowing before the welding current starts up.

21
 PERSONAL PROTECTION
Skull Cap Helmet
Mask

Welding
Jacket helmet lens

Gloves

TIG WELDING HAZARDS

1) Gases - Ozone is formed under the extreme temperature of the arc.
2) Heat
3) Ultra Violet Light - TIG produces one of the highest ratio of ultra
violet light per amperage of any welding process.
4) Fumes - coming from the heating of the base material and the
burning of any contaminates that might be present.
5) Magnetic fields may interfere with medical devices.
6) HF Radiation - can cause interference with other equipment, eg
computers and communication equipment.

22
RECOGNISING YOUR TUNGSTEN
“A” “B” “C” “D” “E” “F” “G”

Electrode “A” has the “ball” end. This pure tungsten was used with
alternating current on aluminium. Notice the end is uniform in shape and
possesses a “shiny bright” appearance.
Electrode “B” is a 2% thoriated tungsten ground to a taper and was used
with direct current straight polarity.
Electrode “C” is a 2% thoriated tungsten which was used with alternating
current on aluminium. Note that this electrode has several small ball shaped
projections rather than a round complete “ball end” like the pure tungsten.
Electrode “D” is a pure tungsten used with alternating current on aluminium.
This electrode was subjected to a current above the rated capacity. Notice the
“ball” started to droop to one side. It becomes very molten during operation
and continuing to operate would have caused the molten end to drop into the
weld puddle.
Electrode “E” is a pure tungsten that was tapered to a point and used on
direct current straight polarity. Notice the “ball” tip characteristic of the pure
tungsten. Pointing of pure tungsten is not recommended as the extreme
point will always melt when the arc is established. The electrode in this
illustration melted back, however, often times the point may melt and drop
into the weld puddle.
Electrode “F” was severely contaminated by touching the filler rod to the
tungsten. In this case the contaminated area must be broken off and the
electrode reshaped as desired.
Electrode “G” did not have sufficient gas “post-flow”. Notice the black surface
which is oxidized because the atmosphere contacted the electrode before it
cooled sufficiently. If this electrode were used the oxidized surface will flake
off and drop into the weld puddle. Post-flow time should be increased so the
appearance is like electrode “A” after welding.

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 OPERATOR INSPECTION FOR WELD QUALITY

PROBLEM: CAUSE:
• Excessive build up Welding current too low
• Poor penetration
• Poor fusion at edges

PROBLEM: CAUSE:
• Bead too wide and flat Welding current too high
• Poor penetration
• Excessive burn through

PROBLEM: CAUSE:
• Bead too small Travel speed too fast
• Insufficient penetration
• Ripples widely spaced

PROBLEM: CAUSE:
• Bead too wide Travel speed too slow
• Excessive build up
• Excessive penetration

PROBLEM: CAUSE:
• Undercut Welding current too high
• Insufficient weld deposit and/or wrong placement of
• Uneven penetration filler rod

PROBLEM: CAUSE:
• Poor penetration Faulty joint preparation and
• Poor fusion too low welding current

PROBLEM: CAUSE:
• Proper build-up Correct technique and
• Good appearance current setting
• good penetration
• Bead edges fused in

PROBLEM: CAUSE:
• No undercut Correct technique and
• Legs of fillet weld equal current setting
to metal thickness
• Slightly convex bead face

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 TIG TROUBLESHOOTING GUIDE
Problem Cause Solution
1. Inadequate gas flow 1. Increase gas flow
2. Improper size electrode for current required 2. Use larger electrode
Excessive 3. Operating of reverse polarity 3. Use larger electrode or change polarity
Electrode 4. Electrode contamination 4. Remove contaminated portion, then prepare again
Consumption 5. Excessive heating inside torch 5. Replace collet, try wedge collet or reverse collet
6. Electrode oxidising during cooling 6. Increase gas post flow time to 1 sec. per 10 amps
7. Shield gas incorrect 7. Change to proper gas (no oxygen or CO2)
1. Incorrect voltage (arc too long) 1. Maintain short arc length
2. Current too low for electrode size 2. Use smaller electrode or increase current
3. Electrode contaminated 3. Remove contaminated portion, then prepare again
4. Joint too narrow 4. Open joint groove
Erratic 5. Contaminated shield gas, dark stains 5. The most common cause is moisture or aspirated air
Arc on the electrode or weld bead indicate in gas stream. Use welding grade gas only. Find the
contamination source of the contamination and eliminate it promptly
6. Base metal is oxidised, dirty or oily 6. Use appropriate chemical cleaners, wire brush, or
abrasives prior to welding
1. Poor scratch starting technique 1. Many codes do not allow scratch starts. Use copper
strike plate. Use high frequency arc starter
2. Excessive current for tungsten size used 2. Reduce the current or use larger electrode
3. Accidental contact of electrode with puddle 3. Maintain proper arc length
4. Accidental contact of electrode to filler rod 4. Maintain a distance between electrode and filler
5. Using excessive electrode extension metal
Inclusion of 5. Reduce the electrode extension to recommended
Tungsten or 6. Inadequate shielding or excessive draughts limits
Oxides in 6. Increase gas flow, shield arc from wind, or use gas
Weld 7. Wrong gas lens
7. Do not use ArO2 or ArCO2 GMA (MIG) gases for TIG
8. Heavy surface oxides not being removed welding
8. Use ACHF, adjust balance control for maximum
cleaning, or wire brush and clean the weld joint prior
to welding.
1. Entrapped impurities, hydrogen, air, 1. Do not weld on wet material. Remove condensation
nitrogen, water vapour from line with adequate gas pre-flow time
2. Defective gas hose or loose connection 2. Check hoses and connections for leaks
3. Filler material is damp (particularly 3. Dry filler metal in oven prior to welding
aluminium) 4. Replace filler metal
Porosity in 4. Filler material is oily or dusty 5. Change to a different alloy composition which is
Weld Deposit 5. Alloy impurities in the base metal such as weldable. These impurities can cause a tendency to
sulphur, phosphorous, lead and zinc crack when hot
6. Excessive travel speed with rapid freezing 6. Lower the travel speed
of weld trapping gases before they escape
7. Contaminated shield gas 7. Replace the shielding gas
1. Hot cracking in heavy section or with metals 1. Preheat, increase weld bead cross-section size,
which are hot shorts change weld bead contour. Use metal with fewer
alloy impurities
2. Crater cracks due to improperly breaking 2. Reverse direction and weld back into previous weld
the arc or terminating the weld at the joint at edge. Use Amptrak or foot control to manually
edge down slope current
Cracking in 3. Post weld cold cracking, due to excessive 3. Preheat prior to welding, use pure or non-
Welds joint restraint, rapid cooling, or hydrogen contaminated gas. Increase the bead size. Prevent
embrittlement craters or notches. Change the weld joint design
4. Centreline cracks in single pass welds 4. Increase bead size. Decrease root opening, use
preheat, prevent craters
5. Underbead cracking from brittle 5. Eliminate sources of hydrogen, joint restraint, and
microstructure use preheat
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 TIG TROUBLESHOOTING GUIDE (continued)
Problem Cause Solution
1. Gas flow blockage or leak in hoses or torch 1. Locate and eliminate the blockage or leak
2. Excessive travel speed exposes molten 2. Use slower travel speed or carefully increase the
weld to atmospheric contamination flow rate to a safe level below creating excessive
Inadequate turbulence. Use a trailing shield cup
Shielding 3. Wind or draughts 3. Set up screens around the weld area
4. Excessive electrode stickout 4. Reduce electrode stickout. Use a larger size cup
5. Excessive turbulence in gas stream 5. Change to gas saver parts or gas lens parts
1. Induced magnetic field from DC weld 1. Change to ACHF current. Rearrange the split ground
Arc current connection
Blow 2. Arc is unstable due to magnetic influences 2. Reduce weld current and use arc length as short as
possible
1. Short water cooled leads life 1. Verify coolant flow direction, return flow must be on
the power cable lead
2. Cup shattering or cracking in use 2. Change cup size or type, change tungsten position,
refer to chart
3. Short collet life 3. Ordinary style is split and twists or jams, change to
Short Parts wedge style
Life 4. Short torch head life 4. Do not operate beyond rated capacity, use water
cooled model, do not bend rigid torches
5. Gas hoses ballooning, bursting, or blowing 5. Incorrect flowmeter, TIG flowmeters operate at 35 psi
off while hot with low flows. MIG flowmeters operate with high
flows at 65 psi or more.

26