215 994 A 2008 03 −
Processes TIG (GTAW) Welding
Guidelines For Gas Tungsten Arc Welding (GTAW)
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TA'! $F "$%T!%T !"T#$% 1 AF!T AF!T P&!" P&!"AT AT#$% #$% 3 &!A !F$&! !F$&! #%G #%G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
−
1-1. S!bol S!bol "sage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2. Ar# Welding Welding $a%ards $a%ards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3. Additional Additional S!bols S!bols &or Installa Installation' tion' eratio eration' n' And *aintenan *aintenan#e #e . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-+. ,aliornia ,aliornia roosition roosition / Warnings Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+
1-. rin#ial Saet Saet Standards Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-/. *& Ino Inor!a r!ation tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+ +
!"T#$% 2 P&#%"#P'! P&#%"#P'! $F GA T%GT!% A&" W!'#%G W!'#%G (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . −
2-1.
ro#ess es#rition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2.
Sele#ting A GTAW owersour #e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3.
Ti#al GTA W Welding Sste! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
/
!"T#$% * GA T%GT!% A&" A&" W!'#%G (GTAW) P&$"!&! P&$"!&! . . . . . . . . . . . . . . . . . . . . . . . . . . . −
3-1.
Ti#al GTA W Welding Set-" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
!"T#$% 4 !'!"T#% !'!"T#%G G A% P&!PA P&!PA&#%G &#%G A T%G T%GT!% T!% F$& " $& A" W!'#%G W!'#%G . . . . . . . . . . . . . −
+ ,
+-1.
Sele#ting Tungsten le#trode le#trode (Wear ,lean glo4es To re4ent ,onta!ination Tungsten) . . . . . .
8
+-2.
rearing Tungsten le#trode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
!"T#$% 5 GTAW WA-!F$&M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
!"T#$% / A&" 0AP#%G 0AP#%G "APA#'#T#! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
−
−
/-1.
Ar# Starting Wit6 ieren t olarities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
/-2.
7alan#e ,ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
/-3.
A, &reuen# Ad9ust!ent ,ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
/-+.
A!erage Ad9ust ,ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
/-.
&reuen# Ad9ust!ent ,ontro l - /0$% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
/-/.
&reuen# Ad9ust!ent ,ontro l - 200$% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
!"T#$% + T#G 0#!'#%G 0#!'#%G GA! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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-1. S6ielding Gases Gases &or TIG Welding Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . !"T#$% , G#!'#%! G#!'#%! F$& GTAW W!'#%G W!'#%G (T#G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1+ 15
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8-1.
:it-Ar# And $& TIG Start ro#edure s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
8-2.
Tor#6 *o4e!ent *o4e!ent uring Welding Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/
8-3.
Suggested In4erter ower Sour#e Starting ara!eters &or Various Alu!inu! ;oints . . . . . . . . . . .
1
8-+.
TIG Welding Welding Te#6niues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
8-.
Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
!"T#$% 9 GTAW T&$'!0$$T#%G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
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5-1.
Troubles6ooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
!"T#$% 1
—
AF!T P&!"AT#$% 3 &!A !F$&! #%G so! <200 0+ 0+ —
+
Protect oursel and ot6ers rom in7ur 8 read and ollow t6ese recautions.
131. m m:ol sage A%G!&; #ndicates a 6a
oided= will result in deat6 or serious in7ur. T6e ossi:le 6a
#ndicates a 6aoided= could result in deat6 or serious in7ur. T6e ossi:le 6a
− Indicates statements not related to personal injury.
Indicates ° instructions.
special
T6is grou o s!bo s!bols ls !eans !eans Warnin Warning= g= Wat#6 Wat#6 ut= :,T>I, S$,?' *VI@G A>TS' and $T A>TS 6a%ards. ,onsult s!- bols and related instru#tions below or ne#essar a#tions to a4oid t6e 6a%ards.
132. 132. Arc Weld Weldin ing g 0a< 0a
T6e sm:ols s6own :elow are used t6roug6out t6is manual to call attention to and identi ossi:le 6aoid t6e 6aen :elow is onl a summar o t6e more comlete saet inormation ound in t6e aet tandards listed in ection 135. &ead and ollow all aet tandards. $nl @ualiied ersons s6ould install= oerate= maintain= and reair t6is unit. uring oeration= ee e>er:od= eseciall c6ildren= awa.
!'!"T&#" 0$"B can ill. Tou#6ing li4e ele#tri#al arts #an #ause atal s6o#s s6o#s or se4ere burns. T6e ele#trode ele#trode and wor #ir#uit is ele#tri#all li4e w6ene4er t6e outut is on. T6e inut ower #ir#uit and !a#6ine internal #ir#uits are also li4e w6en ower is on. In se!iauto!ati# or auto!ati# wire welding' t6e wire' wire reel' dri4e roll 6ousing' and all !etal arts tou#6ing t6e welding wire are ele#tri#all ele#tri#all li4e. In#orre#t In#orre#tl l installed installed or i!roerl grounded eui!ent is a 6a%ard. •
o not tou#6 li4e ele#tri#al
arts. Wear dr' 6ole-ree insulating glo4es and bod rote#tion. Insulate oursel ro! wor and ground using dr insulating !ats or #o4ers big enoug6 to re4ent an 6si#al #onta#t wit6 t6e wor or ground. o not use A, outut in da! areas' i !o4e!ent is #onined' or i t6ere is a danger o alling. "se A, outut @:B i reuired or t6e welding ro#ess. I A, outut is reuired' use re!ote outut #ontrol i resent on unit. Additional saet re#autions are reuired w6en an o t6e oll ollow ow-- ing ele#tr ele#tri#a i#all ll 6a%ard 6a%ardous ous #ondit #ondition ions s are resentC in da! lo#ations lo#ations or w6ile wearing wearing wet #lot6in #lot6ingD gD on !etal stru#tures su#6 as loors' gratings' or s#aoldsD w6en in #ra!ed ositions su#6 as sitting' neeling' or lingD or w6en t6ere is a 6ig6 ris o una4oid- able or a##idental #onta#t wit6 t6e worie#e or ground. &or t6ese #onditions' use t6e ollowing eui!ent in order resentedC 1) a se!iauto!ati# , #onstant 4oltage (wire) welder' 2) a , !anual (sti#) welder' or 3) an A, welder wit6 redu#ed oen-#ir#uit oen-#ir#uit 4olt- age. In !ost situations' use o a ,' #onstant 4oltage wire welder is re#o!!ended. And' do not wor alone= •
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is#onne#t inut ower or sto engine beore installing or ser4i#ing t6is eui!ent. :o#outEtagout inut ower a##ording to S$A 25 ,&> 1510.1+ (see Saet Standards). roerl install and ground t6is eui!ent a##ording to
its wnerFs *anual and national' national' state' and lo#al #odes.
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Alwas 4eri t6e sul ground #6e# and be sure t6at inut ower #ord ground wire is roerl #onne#ted to ground ter!inal in dis#onne#t bo or t6at #ord lug is #onne#ted to a roerl grounded re#eta#le outlet. —
W6en !aing inut #onne#tions' atta#6 roer grounding #ondu#- tor irst double-#6e# #onne#tions. —
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?ee #ords dr' ree o oil and grease' and rote#ted ro! 6ot !etal and sars. &reuentl inse#t inut ower #ord or da!age or bare wiring rela#e #ord i!!ediatel i da!aged bare wiring #an ill. Turn o all eui!ent w6en not in use.
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o not use worn' da!aged' undersi%ed' or oorl sli#ed #ables.
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o not drae #ables o4er our bod.
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?ee all anels and #o4ers se#urel in la#e.
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,la! wor #able wit6 good !etal-to-!etal #onta#t to worie#e or wortable as near t6e weld as ra#ti#al. Insulate wor #la! w6en not #onne#ted to worie#e to re4ent #onta#t wit6 an !etal ob9e#t. o not #onne#t !ore t6an one ele#trode or wor #able to an single weld outut ter!inal.
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Wear a saet 6arness i woring abo4e loor le4el.
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I eart6 grounding o t6e worie#e is reuired' ground it dire#tl wit6 a searate #able. o not tou#6 ele#trode i ou are in #onta#t wit6 t6e wor' ground' or anot6er ele#trode ro! a dierent !a#6ine.
#G%#F#"A%T " -$'TAG! e?ists in in>erter3te welding ower sources ater remo>al o inut ower. •
Turn in4erter' dis#onne#t inut ower' and dis#6arge inut #aa#itors a##ording to instru#tions in *aintenan#e Se#tion beore tou#6ing an arts.
0$T PA&T can cause se>ere :urns.
o not tou#6 ele#trode 6olders #onne#ted to two welding !a#6ines at t6e sa!e ti!e sin#e double oen-#ir#uit 4oltage will be resent.
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"se onl well-!aintained eui!ent. >eair or rela#e da!aged arts at on#e. *aintain unit a##ording to !anual.
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o not tou#6 6ot arts bare 6anded. Allow #ooling eriod beore woring on gun or tor#6. To 6andle 6ot arts' use roer tools andEor wear 6ea4' insulated welding glo4es and #lot6ing to re4ent burns. 21 55+ age 1
FM! A% GA! can :e 6a
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Welding rodu#es u!es and gases. 7reat6ing t6ese u!es and gases #an be 6a%ardous to our 6ealt6.
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?ee our 6ead out o t6e u!es. o not breat6e t6e u!es. I inside' 4entilate t6e area andEor use lo#al or#ed 4entilation at t6e ar# to re!o4e welding u!es and gases. I 4entilation is oor' wear an aro4ed air-sulied resirator. >ead and understand t6e *aterial Saet ata S6eets (*SSs) and t6e !anua#turerFs instru#tions or !etals' #onsu!ables' #oatings' #leaners' and degreasers. Wor in a #onined sa#e onl i it is well 4entilated' or w6ile wearing an air-sulied resirator. Alwas 6a4e a trained wat#6- erson nearb. Welding u!es and gases #an disla#e air and lower t6e ogen le4el #ausing in9ur or deat6. 7e sure t6e breat6- ing air is sae.
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o not use welder to t6aw ro%en ies. >e!o4e sti# ele#trode ro! 6older or #ut o welding wire at #onta#t ti w6en not in use. Wear oil-ree rote#ti4e gar!ents su#6 as leat6er glo4es' 6ea4 s6irt' #uless trousers' 6ig6 s6oes' and a #a. >e!o4e an #o!bustibles' su#6 as a butane lig6ter or !at#6es' ro! our erson beore doing an welding. Ater #o!letion o wor' inse#t area to ensure it is ree o sars' glowing e!bers' and la!es.
"se onl #orre#t uses or #ir#uit breaers. o not o4ersi%e or b- ass t6e!. &ollow reuire!ents in S$A 1510.22 (a) (2) (i4) and @&A 17 or 6ot wor and 6a4e a ire wat#6er and etinguis6er nearb. •
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F'#%G M!TA' or #&T can in7ure •
o not weld in lo#ations near degreasing' #leaning' or sraing o- erations. T6e 6eat and ras o t6e ar# #an rea#t wit6 4aors to or! 6ig6l toi# and irritating gases.
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o not weld on #oated !etals' su#6 as gal4ani%ed' lead' or #ad!iu! lated steel' unless t6e #oating is re!o4ed ro! t6e weld area' t6e area is well 4entilated' and w6ile wearing an airsulied resirator . T6e #oatings and an !etals #ontaining t6ese ele!ents #an gi4e o toi# u!es i welded.
#'P $F GA can in7ure or ill. •
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A&" &A can :urn ees and sin.
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Wear an aro4ed welding 6el!et itted wit6 a roer s6ade o il- ter lenses to rote#t our a#e and ees w6en welding or wat#6ing (see A@SI H+5.1 and H8.1 listed in Saet Standards). Wear aro4ed saet glasses wit6 side s6ields our 6el!et.
under
"se rote#ti4e s#reens or barriers to rote#t ot6ers ro! las6' glare and sarsD warn ot6ers not to wat#6 t6e ar#. Wear rote#ti4e #lot6ing !ade ro! durable' la!e-resistant !ate- rial (leat6er' 6ea4 #otton' or wool) and oot rote#tion.
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%$#! can damage 6earing. @oise ro! so!e ro#esses or eui!ent #an da!age 6earing.
W!'#%G can cause ire or e?9losion.
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>e!o4e all la!!ables wit6in 3 t (10. !) o t6e welding ar#. I t6is is not ossible' tig6tl #o4er t6e! wit6 aro4ed #o4ers.
o not weld w6ere ling sars #an strie la!!able !aterial. •
rote#t oursel and ot6ers ro! ling sars and 6ot !etal. •
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7e alert t6at welding sars and 6ot !aterials ro! welding #an easil go t6roug6 s!all #ra#s and oenings to ad9a#ent areas.
Wat#6 or ire' and ee a ire etinguis6er nearb. •
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7e aware t6at welding on a #eiling' loor' bul6ead' or artition #an #ause ire on t6e 6idden side. o not weld on #losed #ontainers su#6 as tans' dru!s' or ies' unless t6e are roerl reared a##ording to AWS &+.1 (see Saet Standards). o not weld w6ere t6e at!os6ere !a #ontain la!!able dust' gas' or liuid 4aors (su#6 as gasoline). ,onne#t wor #able to t6e wor as #lose to t6e welding area
Wearers o a#e!aers and ot6er I!lanted *edi#al e4i#es s6ould ee awa.
I!lanted *edi#al e4i#e wearers s6ould #onsult t6eir do#tor and t6e de4i#e !anua#turer beore going near ar# welding' sot welding' gouging' las!a ar# #utting' or indu#tion 6eating oerations.
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Welding on #losed #ontainers' su#6 as tans' dru!s' or ies' #an #ause t6e! to blow u. Sars #an l o ro! t6e welding ar#. T6e ling sars' 6ot worie#e' and 6ot eui!ent #an #ause ires and burns. A##idental #onta#t o ele#trode to !etal ob9e#ts #an #ause sars' elosion' o4er6eating' or ire. ,6e# and be sure t6e area is sae beore doing an welding.
S6ut o s6ielding gas sul w6en not in use. Alwas 4entilate #onined sa#es or use aro4ed air-sulied resirator.
MAG%!T#" F#!' can a55ect #m9lanted Medical )e>ices.
Ar# ras ro! t6e welding ro#ess rodu#e intense 4isible and in4isible (ultra4iolet and inrared) ras t6at #an burn ees and sin. Sars weld. •
Welding' #6iing' wire brus6ing' and grinding #ause sars and ling !etal. As welds #ool' t6e #an t6row o slag. Wear aro4ed saet glasses wit6 side s6ields e4en under our welding 6el!et.
Wear aro4ed ear rote#tion i noise le4el is 6ig6.
as ra#ti#al to re4ent welding #urrent ro! tra4eling long' ossibl unnown at6s and #ausing ele#tri# s6o#' sars' and ire 6a%ards. 21 55+ age 2
"'#%!& can e?lode i damaged. S6ielding gas #linders #ontain gas under 6ig6 ressure. I da!aged' a #linder #an elode. Sin#e gas #linders are nor!all art o t6e welding ro#ess' be sure to treat t6e! #areull. •
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rote#t #o!ressed gas #linders ro! e#essi4e 6eat' !e#6ani- #al s6o#s' 6si#al da!age' slag' oen la!es' sars' and ar#s. Install #linders in an urig6t osition b se#uring to a stationar suort or #linder ra# to re4ent alling or tiing. ?ee #linders awa ro! an welding or ot6er ele#tri#al #ir#uits. @e4er drae a welding tor#6 o4er a gas #linder. @e4er allow a welding ele#trode to tou#6 an #linder. @e4er weld on a ressuri%ed #linder eG)losion will result. —
"se onl #orre#t s6ielding gas #linders' regulators' 6oses' and it- tings designed or t6e se#ii# ali#ationD !aintain t6e! and asso#iated arts in good #ondition. Turn a#e awa ro! 4al4e outlet w6en oening #linder 4al4e. ?ee rote#ti4e #a in la#e o4er 4al4e e#et w6en #linder is in use or #onne#ted or use. "se t6e rig6t eui!ent' #orre#t ro#edures' and sui#ient nu!- ber o ersons to lit and !o4e #linders. >ead and ollow instru#tions on #o!ressed gas #linders' asso#iated eui!ent' and ,o!ressed Gas Asso#iation (,GA) ubli#ation -1 listed in Saet Standards.
13*. Additional m:ols For #nstallation= $eration= And Maintenance F#&! $& !CP'$#$% 6a
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M$-#%G PA&T can cause in7ur.
o not install or la#e unit on' o4er' or near #o!bustible sura#es. o not install unit near la!!ables.
o not o4erload building wiring be sure ower sul sste! is roerl si%ed' rated' and rote#ted to 6andle t6is unit.
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FA''#%G %#T can cause in7ur. •
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"se liting ee to lit unit onl' @T running gear' gas #linders' or an ot6er a##essories. "se eui!ent o adeuate #aa#it to lit and suort unit.
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Sars #an #ause ires ee la!!ables awa.
>ead wnerFs *anual beore using or ser4i#- ing unit. "se onl genuine rela#e!ent arts ro! t6e !anua#turer.
0.F. &A#AT#$% can cause inter5erence.
Allow #ooling eriodD ollow rated dut ##le. >edu#e #urrent or redu#e dut ##le beore starting to weld again. o not blo# or ilter airlow to unit.
Wear a a#e s6ield to rote#t ees and a#e. S6ae tungsten ele#trode onl on grinder wit6 roer guards in a sae lo#ation wearing roer a#e' 6and' and bod rote#tion.
>einstall doors' anels' #o4ers' or guards w6en !aintenan#e is inis6ed and beore re#onne#ting inut ower.
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I using lit ors to !o4e unit' be sure ors are long enoug6 to etend beond oosite side o unit.
F'#%G PA&B can cause in7ur.
$a4e onl ualiied ersons re!o4e doors' anels' #o4ers' or guards or !aintenan#e as ne#essar.
&!A #%T&"T#$%.
$-!&! can cause $-!&0!AT#%G •
?ee awa ro! !o4ing arts su#6 as ans. ?ee all doors' anels' #o4ers' and guards #losed and se#urel in la#e.
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$ig6-reuen# ($.&.) #an interere wit6 radio na4igation' saet ser4i#es' #o!uters' and #o!!uni#ations eui!ent. $a4e onl ualiied ersons a!iliar wit6 ele#troni# eui!ent eror! t6is installation.
T6e user is resonsible or 6a4ing a ualiied ele#tri#ian ro!t- l #orre#t an intereren#e roble! resulting ro! t6e installa- tion. I notiied b t6e &,, about intereren#e' sto using t6e eui!ent at on#e. $a4e t6e installation regularl #6e#ed and !aintained. ?ee 6ig6-reuen# sour#e doors and anels tig6tl s6ut' ee sar gas at #orre#t setting' and use grounding and s6ielding to !ini!i%e t6e ossibilit o intereren#e.
TAT#" (!) can damage P" :oards. •
•
ut on grounded wrist stra 7&> 6andling boards or arts. "se roer stati#-roo bags and boes to store' !o4e' or s6i , boards.
A&" W!'#%G can cause inter5erence. •
M$-#%G PA&T can cause in7ur. •
•
?ee awa ro! !o4ing arts. ?ee awa ro! in#6 oints su#6 as dri4e rolls.
W!'#%G W#&! can cause in7ur. •
•
o not ress gun trigger until instru#ted to do so. o not oint gun toward an art o t6e bod' ot6er eole' or an !etal w6en t6reading welding wire.
•
•
•
•
•
le#tro!agneti# energ #an interere wit6 sensiti4e ele#troni# eui!ent su#6 as #o!uters and #o!uter-dri4en eui!ent su#6 as robots. 7e sure all eui!ent in t6e welding area is ele#tro!agneti#all #o!atible.
To redu#e ossible intereren#e' ee weld #ables as s6ort as ossible' #lose toget6er' and down low' su#6 as on t6e loor. :o#ate welding oeration 100 !eters ro! an sensiti4e ele#- troni# eui!ent. 7e sure t6is welding !a#6ine grounded a##ording to t6is !anual.
is
installed
and
I intereren#e still o##urs' t6e user !ust tae etra !easures su#6 as !o4ing t6e welding !a#6ine' using s6ielded #ables' using line ilters' or s6ielding t6e wor area.
21 55+ age 3
134. "aliornia Proosition /5 Warnings Welding or cutting e@uiment roduces umes or gases w6ic6 contain c6emicals nown to t6e tate o "aliornia to cause :irt6 deects and= in some cases= cancer. ("aliornia 0ealt6 D aet "ode ection 25249.5 et se@.)
For Gasoline !nginesE !ngine e?6aust contains c6emicals nown to t6e tate o "aliornia to cause cancer= :irt6 deects= or ot6er reroduc3 ti>e 6arm. For iesel !nginesE
atter osts= terminals and related accessories contain lead and lead comounds= c6emicals nown to t6e tate o "aliornia to cause cancer and :irt6 deects or ot6er reroducti>e 6arm. Was6 6ands ater 6andling.
iesel engine e?6aust and some o its constituents are nown to t6e tate o "aliornia to cause cancer= :irt6 deects= and ot6er reroducti>e 6arm.
135. Princial aet tandards Safety in Welding, Cutting, and Allied Processes, A@SI Standard H+5.1' ro! Global ngineering o#u!ents (6oneC 1-8-+13-18+' websiteC www.global.i6s.#o!). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, A!eri#an Welding So#iet Standard AWS &+.1' ro! Global ngineering o#u!ents (6oneC 1-8-+13-18+' websiteC www.global.i6s.#o!). National lectrical Code, @&A Standard 0' ro! @ational &ire rote#- tion Asso#iation' .. 7o 5101' Juin#' *A 022/5-5101 (6oneC /1-0-3000' websiteC ww w.na.or g and www. sar.org). Safe !andling of Compressed "ases in Cylinders, ,GA a!6let 1' ro! ,o!ressed Gas Asso#iation' +221 Walne >oad' t6 &loor' ,6antill' VA 2011 (6oneC 03-88-200' websiteCww w.#ganet.#o!). Code for Safety in Welding and Cutting, ,SA Standard W11.2' ro! ,anadian Standards Asso#iation' Standards Sales' 0/0 *ississauga'
ntario' ,anada :+W @S (6oneC 800-+/3-/2 or in Toronto +1/-+-+0++' websiteC ww w.#sainternational.org). Safe Practice #or $ccupational And ducational ye And #ace Protec- tion, A@SI Standard H8.1' ro! A!eri#an @ational Standards Institute' 2 West +3rd Street' @ew Bor' @B 1003/K8002 (6oneC 212-/+2-+500' websiteC www.ansi.org). Standard for #ire Pre%ention &uring Welding, Cutting, and $ther !ot Wor', @&A Standard 17' ro! @ational &ire rote#tion Asso#iation' .. 7o 5101' Juin#' *A 022/5-5101 (6oneC /10-3000' web- siteC www.na.org. S$A' ##uational Saet and $ealt6 Standards or General Indus- tr' Title 25' ,ode o &ederal >egulations (,&>)' art 1510' Subart J' and art 152/' Subart ;' ro! ".S. Go4ern!ent rinting i#e' Suer- intendent o o#u!ents' .. 7o 315+' ittsburg6' A 120-5+ (6oneC 1-8//-12-1800) (t6ere are 10 >egional i#es6one or >egion ' ,6i#ago' is 312-33-2220' websiteC www.os6a.go4).
13/. !MF #normation ,onsiderations About Welding And T6e e#ts :ow &reuen# le#tri# And *agneti# &ields
1.
Welding #urrent' as it lows t6roug6 welding #ables' will #ause ele#tro- !agneti# ields. T6ere 6as been and still is so!e #on#ern about su#6 ields. $owe4er' ater ea!ining !ore t6an 00 studies sanning 1 ears o resear#6' a se#ial blue ribbon #o!!ittee o t6e @ational >esear#6 ,oun#il #on#luded t6atC LT6e bod o e4iden#e ' in t6e #o!!itteeFs 9udg!ent' 6as not de!onstrated t6at eosure to ower- reuen# ele#tri# and !agneti# ields is a 6u!an-6ealt6 6a%ard.M $owe4er' studies are still going ort6 and e4iden#e #ontinues to be ea!ined. "ntil t6e inal #on#lusions o t6e resear#6 are rea#6ed' ou !a wis6 to !ini!i%e our eosure to ele#tro!agneti# ields w6en welding or #utting.
2. Arrange #ables to one side and awa ro! t6e oerator.
To redu#e !agneti# ields in t6e worla#e' use t6e ollowing ro#eduresC
?ee #ables #lose toget6er b twisting or taing t6e!' or using a #able #o4er.
3. o not #oil or drae #ables around our bod. +.
?ee welding ower sour#e and #ables as ar awa ro! oera- tor as ra#ti#al.
.
,onne#t wor #la! to worie#e as #lose to t6e weld as ossi- ble.
A:out #mlanted Medical e>icesE I!lanted *edi#al e4i#e wearers s6ould #onsult t6eir do#tor and t6e de4i#e !anua#turer beore eror!ing or going near ar# welding' sot welding' gouging' las!a ar# #utting' or indu#tion 6eating oerations. I #leared b our do#tor' t6en ollowing t6e abo4e ro#edures is re#o!- !ended.
21 55+ age +
!"T#$% 2
—
P&#%"#P'! $F GA T%GT!% A&" W!'#%G (GTAW)
231. Process escrition Gas Tungsten Ar# Welding (GTAW)' also nown as tungsten inert gas (TIG) welding is a ro#ess t6at rodu#es an ele#tri# ar# !aintained between a non#onsu!able tungsten ele#trode and t6e art to be welded. T6e 6eat-ae#ted %one' t6e !olten !etal and t6e tungsten ele#trode are all s6ielded ro! at!os6eri# #onta!ination b a blanet o inert gas ed t6roug6 t6e GTAW tor#6. Inert gas (usuall Argon) is ina#ti4e or dei#ient in a#ti4e #6e!i#al roerties. T6e s6ielding gas ser4es to blanet t6e weld and e#lude t6e a#ti4e roerties in t6e surrounding air. Inert gases su#6 as Argon and $eliu! do not #6e!i#all rea#t or #o!bine wit6 ot6er gases. T6e ose no odor and are transarent' er!itting t6e t6e welder !ai!u! 4isibilit o t6e ar#. In so!e instan#es $drogen gas !a be added to e6an#e tra4el seeds. T6e GTAW ro#ess #an rodu#e te!eratures o u to 3'000 ° & (15'+2/° ,). T6e tor#6 #ontributes 6eat onl to t6e worie#e. I iller !etal is reuired to !ae t6e weld' it !a be added !anuall in t6e sa!e !anner as it is added in t6e oa#etlene welding ro#ess. GTAW is used to weld stainless steel' ni#el allos su#6 as *onel ® and In#onel®' titaniu!' alu!inu!' !agnesiu!' #oer' brass' bron%e and e4en gold. GTAW #an also weld dissi!ilar !etals to one anot6er su#6 as #oer to brass and stainless to !ild steel. Ad4antages o GTAW weldingC ,on#entrated Ar# - er!its in oint #ontrol o 6eat inut to t6e worie#e resulting in a narrow 6eat-ae#ted %one •
•
•
•
@o Slag - @o reuire!ent or lu wit6 t6is ro#essD t6ereore no slag to obs#ure t6e welderFs 4ision o t6e !olten weld ool @o Sars or Satter - @o transer o !etal a#ross t6e ar#. @o !olten globules o satter to #ontend wit6 and no sars rodu#ed i !aterial being welded is ree o #onta!inants :ittle S!oe or &u!es - ,o!ared to ot6er ar#-welding ro#esses lie sti# or lu #ored welding' ew u!es are rodu#ed. $owe4er' t6e base !etals being welded !a #ontain #oatings or ele!ents su#6 as lead' %in#' #oer' ni#el and so on' t6at !a rodu#e 6a%ardous u!es. ?ee our 6ead and 6el!et out o t6e u!es rising o t6e worie#e. 7e sure t6at roer 4entilation is sulied' ese#iall in a #onined sa#e.
•
Welds !ore !etals and !etal allos t6an an ot6er ro#ess
•
Good or welding t6in !aterial
isad4antages o GTAW weldingC •
Slower tra4el seeds t6an ot6er ro#esses
•
:ower iller !etal deosition rates
•
$and-ee #oordination is a reuired sill
•
7rig6ter "V ras t6an ot6er ro#esses
•
ui!ent #osts #an be 6ig6er t6an ot6er ro#esses
•
,on#entrations o s6ielding gas !a build u and disla#e ogen w6en welding in #onined areas 4entilate t6e area andEor use lo#al or#ed 4entilation at t6e ar# to re!o4e welding u!es and gases. I 4entilation is oor' wear an aro4ed air-sulied resirator —
232. electing A GTAW Powersource Bour #6oi#e o TIG owersour#e is dri4en b t6e te o !aterial and t6i#ness ou will weld. T6is will deter!ine w6et6er ou reuire a !a#6ine or all weldable !etals e#et Alu!inu! (,) or one t6at is or all weldable !etals (A,E,). Ite!s to #onsiderC •
Te o !etal to be welded - (Alu!inu!' Steel' Stainless et#.)
•
T6i#ness o !aterials to be welded
•
a#age solution t6at suits t6e welding ali#ation
•
A##essor #o!onents t6at add eror!an#e to t6e sste! 21 55+ age
23*. Tical GTAW Welding stem
5
8
1
/
>e. 80+ 8+/-A
+ 3
2
1 Welding ower Sour#e ,onstant ,urrent (,,) 2 &oot ,ontrol 3 Worie#e
21 55+ age /
—
+
Wor ,la!
,oolant In $ose
Tor#6
8
,ooling Sste!
5
S6ielding Gas
/ ,oolant ut $ose
!"T#$% *
—
GA T%GT!% A&" W!'#%G (GTAW) P&$"!&!
*31. Tical GTAW Welding et3 ;
Grinding t6e tungsten elec3 trode roduces dust and l3 ing sars w6ic6 can cause in7ur and start ires. se lo3 cal e?6aust (orced >entila3 tion) at t6e grinder or wear an aro>ed resirator. &ead M or saet inormation. "onsider using cerium or lant6anum :ased tungsten instead o t6oriated. T6o3 rium dust contains low3le>el radioacti>e material. Proer3 l disose o grinder dust in an en>ironmentall sae wa. Wear roer ace= 6and= and :od rotection. Bee lam3 ma:les awa.
1
Worie#e
3 2
+
50° 1
*ae sure worie#e is #lean beore welding. 2 Wor ,la! la#e as #lose to t6e weld as ossible.
10 1° —
3
+ /
10 2° —
Tor#6
+ &iller Ali#able) ,u
>od (I
Gas
/ Tungsten le#trode Sele#t and reare tungsten a##ording to Se#tion +.
/
GuidelinesE T6e inside dia!eter o t6e gas #u s6ould be at least t6ree ti!es t6e tungsten dia!eter to ro4ide adeuate s6ielding gas #o4erage. (&or ea!le' i tungsten is 1E1/ in. dia!eter' gas #u s6ould be a !ini!u! o 3E1/ in. dia!eter.
1E1/ in 3E1/ in 7otto! View Gas ,u
Tungsten etension is t6e distan#e t6e tungsten etends out gas #u o tor#6. T6e tungsten etension s6ould be no greater t6an t6e inside dia!eter o t6e gas #u. Ar# lengt6 is t6e distan#e ro! t6e tungsten to t6e worie#e.
>e. ST-1/1 852
21 55+ age
!"T#$% 4
—
!'!"T#%G A% P&!PA&#%G A T%GT!% F$& " $& A" W!'#%G gtaw
W6ene>er ossi:le and ractical= use " weld outut instead o A" weld outut.
431. electing Tungsten !lectrode ( Wear "lean glo>es To Pre>ent "ontamination $ Tungsten ) Amerage &ange 3 Gas Te♦ 3 Polarit !lectrode iameter
("!%)
—
Argon
irect "urrent !lectrode %egati>e (For se Wit6 Mild $r tainless teel)
A"
—
Argon
alance "ontrol /5 !lectrode %egati>e (For se Wit6 Aluminum)
2 "eria ($range and)= 1.5 'ant6anum (Gra and)= $r 2 T6orium (&ed and) Allo Tungstens .010 in. (1 !!)
" to 2
" to 20
.020 in. (1 !!)
1-+0
1-3
.0+0 in. (1 !!)
2-8
20-80
1E1/ in. (1./ !!)
0-1/0
0-10
3E32 in. (2.+ !!)
13-23
130-20
1E8 in. (3.2 !!)
20-+00
22-3/0
E32 in. (+.0 !!)
+00-00
300-+0
3E1/ in. (+.8 !!)
00-0
+00-00
1E+ in. (/.+ !!)
0-1000
/00-800
Pure Tungsten (Green and)
♦Ti#al
.0+0 in. (1 !!)
ure Tungsten @ot >e#o!!ended
10-/0
1E1/ in. (1./ !!)
&or ,@ Argon
0-100
—
3E32 in. (2.+ !!)
100-1/0
1E8 in. (3.2 !!)
10-210
argon s6ielding gas low rates are 11 to 3 #6 (#ubi# eet er 6our).
&igures listed are a guide and are a #o!osite o re#o!!endations ro! A!eri#an Welding So#iet (AWS) and ele#trode !anua#turers.
21 55+ age 8
432. Prearing Tungsten !lectrode
Grinding t6e tungsten electrode roduces dust and ling sars w6ic6 can cause in7ur and start ires. se local e?6aust (orced >entilation) at t6e grinder or wear an aro>ed resirator. &ead M or saet inor3 mation. "onsider using tungsten containing ceria= lant6ana= or ttria instead o t6oria. t6oriated electrodes contains low3le>el radioacti>e material. Proerl disose o grinder dust in an en>iron3 mentall sae wa. Wear roer ace= 6and= and :od rotection. Bee lamma:les awa.
Prearing Tungsten For " !lectrode %egati>e ("!%) Welding or A" Welding Wit6 #n>erter Mac6ines 1 2-1E2 Ti!es le#trode ia!eter
>adial Grinding ,auses Wandering Ar#
2 3 1
Grinding W6eel
Grind end o tungsten on ine grit' 6ard abrasi4e w6eel beore welding. o not use w6eel or ot6er 9obs or tungsten #an be#o!e #onta!inated #ausing lower weld ualit. 2 Tungsten le#trode A 2N #eriated tungsten is re#o!!ended. 3
+ Wrong Tungsten rearation Ideal Tungsten rearation Ar#
—
Stable
&lat
ia!eter o t6is lat deter!ines a!erage #aa#it. + Straig6t Ground Grind lengt6wise' not radial.
Prearing Tungsten For A" Welding Wit6 P6ase "ontrol Mac6ines
1 Tungsten le#trode 1 1-1E2 Ti!es le#trode ia!eter —
A ure re#o!!ended.
tungsten
is
2 7alled nd 1
2
7all end o tungsten b aling A, a!er- age re#o!!ended or a gi4en ele#trode dia!eter (see Se#tion +-1). :et ball on end o t6e tungsten tae its own s6ae.
21 55+ age 5
!"T#$% 5
—
GTAW WA-!F$&M
1
1
A, Sine Wa4e
2
Weld Sa!le
Ti!e +0.0 30.0
H t n e r r u ,
20.0 e g a r e ) ! A
10.0 0.0 10.0
—
—
20.0
—
Ti!e 1E/0 Se#ond
30.0
—
+0.0
—
2
>e. 80 18/-A
1 °
Hero ,rosso4er (he percentage of time spent in the )ero Crosso%er Area affects the *uality of the +elding arc.
Hero ,rosso4er Area
1
H t n e r r u ,
—
>e. 80 18/-A
21 55+ age 10
1 °
Suarewa4e I!osed 4er Sine Wa4e ess time is spent in ero crosso%er +ith s*uare+a%e output.
1
H t n e r r u ,
—
>e. 80 18/-A
1
,on4entional Suarewa4e A,
2
Weld Sa!le
°
1
#aster transition time et+een electrode positi%e and electrode negati%e.
Ti!e +0.0 30.0
H
20.0 e g a r e ) ! A
10.0
t n e r r u ,
0.0
10.0
—
—
20.0
—
30.0
—
+0.0
—
2
>e. 80 18/-A
21 55+ age 11
!"T#$% /
—
A&" 0AP#%G "APA#'#T#!
/31. Arc tarting Wit6 ierent Polarities
°
!lectrode Positi>e tarting
!lectrode %egati>e tarting
re6eats tungsten
reerred or re#ision ,
>eeatable starting
>eeatable starting
,leans wor on starts
@ #leaning on starts
,an da!age tungsten ti
@ da!age to tungsten
Good or A, TIG
A##etable or A,
Arc shaping capailities are enhanced y impro%ed alance control, AC fre*uency control and independent amperage control.
/32. alance "ontrol 1
*ore Ti!e
S6allower enetration. 2
*ore @ Ti!e
eeer enetration' aster tra4el seeds. 1
2
>e. 80 18-A
/3*. A" Fre@uenc Ad7ustment "ontrol 1
:ow A, &reuen#
Sot' wide ar# wit6 s6allower enetration. 2
$ig6 A, &reuen#
&o#used ar# wit6 deeer enetration. 1
2
>e. 80 18-A
/34. #ndeendent Amerage "ontrol 1
*ore A!erage
Wide' s6allow enetration. 2
*ore @ A!erage
@arrow' dee enetration' aster tra4el seeds. 1
2
>e. 80 18-A
21 55+ age 12
/35. Fre@uenc Ad7ustment "ontrol 3 / 0<
1
1
A, Wa4eor!
2
Weld Sa!le
At /0 $% t6e bead doesnFt uite enetrate t6e t6i# alu!inu!. °
H t n e r r u ,
o+er AC fre*uencies create a +ider arc cone.
—
1E/0t6 o a se#ond
2
>e. 80 18/-A
/3/. Fre@uenc Ad7ustment "ontrol 3 2 0<
1
1
A, Wa4eor!
2
Weld Sa!le
At 200 $% t6e bead is !u#6 tig6ter and enetrated t6e t6i#er !etal. °
H t n e r r u ,
!igher AC fre*uencies create a narro+er arc cone.
—
1E200t6 o a se#ond
2
>e. 80 18/-A
21 55+ age 13
!"T#$% +
—
T#G 0#!'#%G GA! gtaw
+31. 6ielding Gases For T#G Welding 1
S6ielding Gas ,linder
Tes o S6ielding GasesC •
1
•
•
Argon $eliu! ArgonE$eliu! *itures
>e. 80+ +15-A
"0A&A"T!&#T#"
A&G
%$0!'#M
A&G$%I0!'#M M#C!
Tra4el Seed
>edu#ed tra4el seeds
&aster tra4el seeds
I!ro4ed tra4el seeds o4er 100N Argon
enetration
>edu#ed enetration
In#reased enetration
I!ro4ed enetration o4er 100N Argon
,leaning
Good #leaning a#tion
:ess #leaning a#tion
,leaning roerties #loser to Argon
Ar# Starting
asier ar# starting
ii#ult ar# starting
I!ro4ed ar# starting o4er 100N $eliu!
Ar# Stabilit
Good ar# stabilit
:ess low a!erage stabilit
I!ro4ed ar# stabilit o4er 100N $eliu!
Ar# ,one
&o#used ar# #one
&lared ar# #one
Ar# #one s6ae !ore o#used t6an wE$eliu!
Ar# Voltage
:ower ar# 4oltages
$ig6er ar# 4oltages
Ar# 4oltages between 100N Argon and $eliu!
&low >ate
:ower low rates 10-30 ,&$
$ig6er low rates (2 ti!es)
$ig6er low rates t6an Argon
,ost
:ower #ost and greater a4ailabilit
$ig6er #ost t6an Argon
,osts 6ig6er t6an Argon
21 55+ age 1+
!"T#$% ,
—
G#!'#%! F$& GTAW W!'#%G (T#G) gtaw
,31.
'i5t3Arc ™
And 0F T#G tart Procedures 'it3Arc tart 1 TIG le#trode 2
Worie#e
Tou#6 tungsten ele#trode to worie#e at weld start oint and enable outut and s6ielding gas wit6 tor#6 trigger' oot #ontrol' or 6and #ontrol. 0old electrode to woriece or 132 seconds' and slowl lit ele#trode. Ar# is or!ed w6en ele#trode is lited.
'it Arc tart Met6od 1
LTou#6M
1 2 Se#onds —
2
@or!al oen-#ir#uit 4oltage is not resent beore tungsten ele#trode tou#6es worie#eD onl a low sensing 4oltage is resent between ele#trode and worie#e. T6e solid-state outut #onta#tor does not energi%e until ater ele#trode is tou#6ing worie#e. T6is allows ele#trode to tou#6 worie#e wit6out o4er6eating' sti#ing' or getting #onta!inated. AlicationE :it-Ar# is used or t6e ,@ or A, GTAW ro#ess w6en $& Start !et6od is not er!itted' or to re- la#e t6e s#rat#6 !et6od. 0F tart
o @T Strie :ie A *at#6=
$ig6 reuen# turns on to 6el start ar# w6en outut is enabled. $ig6 reuen# turns o w6en ar# is started' and turns on w6ene4er ar# is broen to 6el restart ar#. °
(ype of po+er source and out- put polarity may affect +hen high fre*uency turns off after arc is started.
AlicationE $& start is used or t6e ,@ GTAW ro#ess w6en a non#on- ta#t ar# starting !et6od is reuired.
21 55+ age 1
,32. Torc6 Mo>ement uring Welding Tungsten Wit6out Filler &od °
Welding dire#tion
&or! ool
Tilt tor#6
*o4e tor#6 to ront o ool. >eeat ro#ess.
Tungsten Wit6 Filler &od °
Welding dire#tion
&or! ool
Tilt tor#6
>e!o4e rod
1°
Add iller !etal
*o4e tor#6 to ront o ool. >eeat ro#ess.
ST-1/2 002-7
%otes
Work
lik e
a
Pro!
Pr os weld and cut safely. R ead the saf ety rules
the beinnin of this !anual. at
21 55+ age 1/
,3*. uggested #n>erter Power ource tarting Parameters For -arious Aluminum Joints Weld Joints
Ame ra ge
alance
Fre @uenc
ase ase Filler Filler Tungsten Tungsten 6ielding Gas Flow Allo Te iameter Gas Material Material &od Allo T6icness iameter
7utt ;oint
50-120
/-N
/0-120
%$/0/1
1E8 in.
1E8 in.
3/
2N ,eriated
3E32 in.
Argon
1-20 ,&$
T-;oint
100-12
0-N
100-200
%$/0/1
1E8 in.
1E8 in.
3/
2N ,eriated
3E32 in.
Argon
1-20 ,&$
:a ;oint
50-110
0-N
100-10
%$/0/1
1E8 in.
1E8 in.
3/
2N ,eriated
3E32 in.
Argon
1-20 ,&$
,orner ;oint
80-50
/-0N
100
%$/0/1
1E8 in.
1E8 in.
3/
2N ,eriated
3E32 in.
Argon
1-20 ,&$
,34. T#G Welding Tec6ni@ues Ater learning to start and 6old an ar#' ra#ti#e running beads o weld !etal on lat lates using a ull ele#- trode.
utt Joint
$old t6e ele#trode nearl erendi#ular to t6e wor' alt6oug6 tilting it a6ead (in t6e dire#tion o tra4el) will be 6elul. Torc6 Position For Maing a utt Joint
°
50°
(o produce the est results, hold a short arc, tra%el at a uni- form speed, and feed the elec- trode do+n+ard at a constant rate as it melts.
0°
20°
ST-1/2 003 E S-052
$old t6e tor#6 0 degrees to t6e wor.
T3Joint
°
20° Torc6 Position For Maing a T3Joint
(o produce the est results, hold a short arc, tra%el at a uni- form speed, and feed the elec- trode do+n+ard at a constant rate as it melts.
0°
20° 10° ST-1/2 003 E S-052
21 55+ age 1
,34.
T#G Welding Tec6ni@ues ("ontinued) $old t6e tor#6 0 degrees to t6e wor.
+0° 'a Joint
°
Torc6 Position For Maing a 'a Joint
(o produce the est results, hold a short arc, tra%el at a uni- form speed, and feed the elec- trode do+n+ard at a constant rate as it melts.
0°
20° 30°
ST-1/2 003 E S-052
$old t6e tor#6 0 degrees to t6e wor.
Torc6 Position For Maing a "orner Joint
"orner Joint
°
50°
(o produce the est results, hold a short arc, tra%el at a uni- form speed, and feed the elec- trode do+n+ard at a constant rate as it melts.
0°
20°
ST-1/2 003 E S-052
,35. Weld Test
3 3 2 To 3 in. (1-/ !!)
1E+ in. (/.+ !!)
2
2 To 3 in. (1-/ !!) 2
1
1 S-00-7
1
Vise
t6e #ause.
2
Weld ;oint
3
$a!!er
I t6e weld is orous (!an 6oles)' t6e ar# lengt6 was robabl too long.
Strie t6e weld 9oint in t6e dire#tion s6own. A good weld bends o4er but does not brea. I t6e weld breas' ea!ine it to deter!ine
I t6e weld #ontains bits o slag' t6e ar# !a 6a4e been too long or t6e ele#trode was !o4ed in#orre#tl w6i#6 allowed !olten slag to be traed in t6e weld. T6is !a
6aen on a V-groo4e 9oint !ade in se4eral laers and #alls or additional #leaning be- tween laers. I t6e original be4eled sura#e is 4isible t6e !aterial was not ull !elted w6i#6 is oten #aused b insui#ient 6eat or too ast a tra4el seed.
21 55+ age 18
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—
GTAW T&$'!0$$T#%G
931. Trou:les6ooting ;
Turn o welding ower source and disconnect ower :eore trou:les6ooting.
Pro:lemE urning T6roug6 Tungsten Fast Pro:a:le "auses
&emed
Inadeuate gas low.
,6e# to be sure 6ose' gas 4al4e' and tor#6 are not restri#ted or t6e tan is not out o gas. Gas low s6ould ti#all be set at 1 to 20 ,&$.
eration on ele#trode ositi4e (,).
Swit#6 to ele#trode negati4e (,@).
I!roer si%e tungsten or #urrent used.
,6ange tungsten - General urose tungsten si%e is 3E32 in. dia!eter at a !ai!u! o 23 a!s.
#essi4e 6eating in tor#6 bod.
Air-#ooled tor#6es get 4er war!. I using a water-#ooled tor#6' #6e# #oolant low' !a be restri#ted or #oolant !a be low.
Tungsten oidation during #ooling.
?ee s6ielding gas lowing 10-1 se#onds ater ar# stoage (one se#ond or ea#6 10 a!s o weld #urrent).
"se o gas #ontaining ogen or ,2.
"se argon gas 100N.
Tungsten !elting ba# into #u (A,).
I using ure tungsten' #6ange to #eriated or lant6anated. I !a#6ine 6as 7alan#e ,ontrol' ad9ust setting towards !ai!u! enetration (0-50). In#rease tungsten si%e -Tungsten dia!eter !a be too s!all or t6e a!ount o #urrent being used.
Pro:lemE Tungsten "ontamination Pro:a:le "auses
&emed
Tungsten !elting into weld uddle.
"se less #urrent or larger tungsten. "se #eriated (A,)' t6oriated (,)' or lant6anated tungsten.
Tou#6ing tungsten to weld uddle.
?ee tungsten ro! #onta#ting weld uddle. >aise t6e tor#6 so t6at t6e tungsten is o o t6e wor ie#e 1E1/ to 1E8 in.
Pro:lemE 6ielding Gas Pro:a:le "auses Inadeuate or too !u#6 gas low or wrong gas te.
&emed ,6e# low rate (1 to 20 ,&$) and gas te.
Pro:lemE 0ig6 Fre@uenc Present 3 %o Arc Power Pro:a:le "auses
&emed
In#o!lete weld #ir#uit.
,6e# wor #onne#tion . ,6e# all #able #onne#tions.
@o s6ielding gas.
,6e# or gas low at end o tor#6. ,6e# or e!t #linder or #losed s6ut o 4al4e. Gas low s6ould ti#all be set at 1 to 20 ,&$. —
Pro:lemE Porosit and Poor Weld ead "olor Pro:a:le "auses
&emed
,ondensation on base !etal.
:ine s6ould be urged wit6 Argon or a ew !inutes. >e!o4e all #ondensation ro! base !etal beore welding. *etals stored in #old te!eratures will #ondensate w6en eosed to war!
:oose ittings in tor#6 or 6oses.
Tig6ten ittings on tor#6 and all 6oses.
Inadeuate or too !u#6 gas low.
Ad9ust low rate as ne#essar. Gas low s6ould ti#all be set at 1 to 20 ,&$.
ee#ti4e gas 6ose or loose #onne#tion.
>ela#e gas 6ose and #6e# #onne#tions or leas' #uts' or in 6oles.
,onta!inated or i!roer iller !etal.
,6e# iller !etal te. >e!o4e all grease' oil' or !oisture ro! iller !etal. 21 55+ age 15
Pro:lemE Porosit and Poor Weld ead "olor ("ontinued) Pro:a:le "auses 7ase !etal is #onta!inated.
&emed >e!o4e aint' grease' oil' and dirt' in#luding !ill s#ale ro! base !etal.
Pro:lemE ellow Powder or moe on "u3Tungsten iscolor Pro:a:le "auses
&emed
S6ielding gas low rate too low.
In#rease low rate. Gas low s6ould ti#all be set at 1 to 20 ,&$.
In#orre#t s6ielding gas or !iture.
"se argon gas.
Inadeuate ost low.
In#rease ost low ti!e. Set at 10 to 1 se#onds.
I!roer tungsten si%e or #u si%e.
*at#6 tungsten si%e and #u si%e to 9oint being welded. General urose tungsten si%e is 3E32 in. dia!eter and 8 #u.
Tungsten #onta!ination.
?ee tungsten ro! #onta#ting weld uddle. >aise t6e tor#6 so t6at t6e tungsten is o o t6e wor ie#e 1E8 to 1E+ in.
Pro:lemE nsta:le Arc W6ile A" Welding Pro:a:le "auses
&emed
#essi4e re#tii#ation in ar#.
In#rease tra4el seed. In#rease balan#e #ontrol toward !ore enetration. Add iller !etal.
I!roer s6ielding gas.
,6ange s6ielding gas - In so!e #ases' w6en welding on 3E8 to 1E2 in. t6i# alu!inu!' ArgonE$eliu! is used.
In#orre#t ar# lengt6.
"se #orre#t ar# lengt6. Ad9ust t6e tor#6 so t6at t6e tungsten is o o t6e wor ie#e 1E8 to 1E+ in.
Tungsten is #onta!inated.
>e!o4e 1E2 in. o #onta!inated tungsten and reoint tungsten.
7ase !etal is #onta!inated.
>e!o4e aint' grease' oil' and dirt' in#luding !ill s#ale ro! base !etal.
&reuen# set too low.
n welders wit6 ad9ustable A, reuen#' in#rease reuen# to gi4e roer ar# stabilit and dire#- tion. 100 to 180 $ert% is a##etable.
I!roerl reared tungsten
Wit6 Suarewa4e and in4erter !a#6ines' use ointed tungsten. oint will e4entuall round o ater welding.
Pro:lemE nsta:le Arc W6ile " Welding Pro:a:le "auses
&emed
Weld #ir#uit olarit is in#orre#t.
,6e# olarit swit#6 on welder. Sele#t ,@ (ire#t ,urrent le#trode @egati4e).
Tungsten is #onta!inated.
>e!o4e 1E2 in. o #onta!inated tungsten and reoint tungsten.
Ar# too long.
S6orten ar# lengt6. :ower tor#6 so t6at t6e tungsten is o o t6e wor ie#e no !ore t6an 1E1/ to 1E8 in. ,6e# tungsten te or si%e.
7ase !etal is #onta!inated.
>e!o4e aint' grease' oil' and dirt' in#luding !ill s#ale ro! base !etal.
Pro:lemE Arc Wanders W6ile " Welding Pro:a:le "auses I!roer ar# lengt6Etungsten in oor #ondition.
&emed :ower t6e tor#6 so t6at t6e tungsten is o o t6e wor ie#e 1E1/ to 1E8 in. ,lean and s6aren tung- sten. ,6e# tungsten te or si%e.
I!roerl reared tungsten.
Grind !ars s6ould run lengt6wise wit6 tungsten' not #ir#ular. "se roer grinding !et6od and w6eel.
:ig6t gra rosted aearan#e on end o tungsten.
>e!o4e 1E2 in. o tungsten and reoint tungsten.
I!roer gas low.
Gas low s6ould ti#all be set at 1 to 20 ,&$.
21 55+ age 20
Pro:lemE Arc Wanders W6ile A" Welding Pro:a:le "auses
&emed
I!roer tungsten rearation.
Wit6 Suarewa4e and in4erter !a#6ines' use ointed tungsten. oint will e4entuall round o ater welding.
Tungsten is #onta!inated.
>e!o4e 1E2 in. o #onta!inated tungsten and reoint tungsten.
7ase !etal is #onta!inated.
>e!o4e aint' grease' oil' and dirt' in#luding !ill s#ale ro! base !etal.
In#orre#t balan#e #ontrol setting.
In#rease balan#e toward !ore enetration. @or!al 7alan#e ,ontrol setting is 0 - 50.
I!roer tungsten si%e and te.
Sele#t roer si%e and te. General urose tungsten si%e is 3E32 in. dia!eter and #eriated or t6ori- ated.
#essi4e re#tii#ation in ar#.
In#rease tra4el seed. In#rease balan#e setting toward !ore enetration. Add iller !etal.
I!roer s6ielding gas low.
Gas low s6ould ti#all be set at 1 to 20 ,&$.
&reuen# set too low.
In#rease A, reuen# on !a#6ines so euied to stabili%e and dire#t t6e ar#. T6e 6ig6er t6e re- uen#' t6e narrower and deeer t6e enetration.
%otes
0 5 8 5 2 2
MAT!&#A' T0#"B%! GAG!
21 55+ age 21
