Professional Documents
Culture Documents
By L D Poyyara
GTAW
Fusion Welding Process
Arc Between Non-Consumable Tungsten
Rod And Work
Arc & Weld Pool Shielded By Argon
Filler Wire Separately Added To Weld Pool
Welding Torch & Tungsten Rod Cooled by
Flow OF Argon / Cooling Water
Shielding Gas
Ceramic Cup
Arc
Argon Cylinder
HF Unit &
Water Cooling
System
Work
Pedal Switch
Solenoid
Valve
High Frequency
Connection
Power Source
Generator
High Frequency Unit
Water Cooling System
Welding Torch- (Ceramic Cup, Tungsten Rod,
Collet, Gas-lense)
Petal Switch
Argon Gas Cylinder
Pressure Gauge, Regulator, Flow Meter
Earthing Cable With Clamp
Power Source
Provides Electric Energy Arc Heat
Drooping Characteristic
OCV Appx. 90V,
Current Range 40 A to 300 A ( Capacity Of M/s)
Arc Voltage 18V to 26V
Characteristic Of GTAW
Power Source
Drooping Constant Current
V
V1
Vertical
Curve
V2
A1 A2
GTAW TORCH
Torch Handle
Tungsten Rod
Base Metal
Earthing Cable
Arc
Petal Switch
When Petal Pressed
Solenoid valve opens, Argon gas
flows
High Frequency starts jumping from
Switches system tungsten rod
Welding current flows generating an
on And off in
arc across tungsten rod and work.
High frequency gets cut off from the
sequence
system & welding continues.
When Petal Released
1 Current gets cut off, Arc extinguishes
2 Gas flow remains for few more
seconds before it stops.
Cylinder Valve
Pressure gauges
Flow Meter
Flow Regulator
Pressure Regulator
Connection To Torch
Argon Cylinder
Shielding Gas
Argon - Purity 99.95%
Impure Argon Results In Porosities
Purity Verified by Fusing BQ CS plate
Leakage of Argon in Torch Results in
Porosity.
Check Leakage by Closing the Ceramic
Cup With Thump
Back Purging
Applicable to Single
Sided full penetration
Prevents oxidation of
Filler Wire
Welding Torch
root pass from opposite
side of weld
Essential for high alloy
steels, nonferrous
Purging
Purging Gas In
Gas Out
metals and alloys
Root Pass
Purging
Desirable For All
chamber
Material
Purging Gas Commercial
Argon or Nitrogen
Tungsten Rod
Tungsten Rod
Ground to
50 ankle
Filler Wire
Added Separately to the weld pool.
Compatible to base metal
Used in cut length for manual welding.
Used from layer wound spool for
automatic welding.
Sizes :- 0.8, 1, 1.2, 1.6, 2, 2.4 & 3 mm
Always Connect
Electrode Ve
Keep Always Flow
Meter Vertical
Check & Confirm
Argon Purity
Clean Groove & Filler
wire With Acetone
Grind Tungsten Tip to
Point
Donts
Donts
Donts
Defects In GTAW
1. Cracks
3. Porosity
5.Lack Of Penetration
7.Overlap
9. Under Flush
11. Tungsten Inclusion
2. Lack Of Fusion
4. Undercut
6. Excess Penetration
8. Suck Back
10. Burn Through
11.Stray Arcing
Crack
1)
2)
3)
4)
Cause
Wrong Consumable
Wrong Procedure
Improper Preheat
Inadequate Thickness
In Root Pass
crack
1)
2)
3)
4)
Remedy
Use Right Filler Wire
Qualify Procedure
Preheat Uniformly
Add More Filler Wire
in root Pass
Lack Of Fusion
Cause
Remedy
1) Inadequate Current
1) Use Right Current
2) Wrong Torch angle
2) Train /Qualify welder
3) Improper bead placement 3) Train/Qualify Welder
Lack Of Fusion
Porosity
Cause
1) Impure Argon Gas
2) Argon Leak Within Torch
3) Defective Filler Wire
4) Wet surface of BM
5) Rusted / Pitted Filler wire
6) Improper Flow Of Argon
Porosity
Remedy
1) Replace Argon Cylinder
2) Replace Leaking Torch
3) Replace Filler Wire
4) Clean & Warm BM
5) Clean Filler Wire
6) Provide Gas lense
. .
Undercut
Cause
1) Excess Current
2) Excess Voltage
3) Improper Torch angle
Under cut
Remedy
1) Reduce the Current
2) Reduce Arc length
3) Train & Qualify the Welder
Lack Of Penetration*
Cause
1) Excess Root Face
2) Inadequate Root opening
3) Over size Filler Wire
4) Wrong Direction of Arc
5) Improper bead placement
6) Improper weaving technique
* Applicable to SSFPW
LOP
Remedy
1) Reduce Root Face
2) Increase Root Opening
3) Reduce Filler Wire size
4) Train / Qualify Welder
5) Train / Qualify Welder
6) Train & Qualify Welder
Excess Penetration*
Cause
1)Excess root opening
2) Excess Current
3) Inadequate root face
4) Excess Weaving
5) Wrong Direction Of Arc
* Applicable to SSFPW
Excess Penetration
1)
2)
3)
4)
5)
Remedy
Reduce root gap
Reduce Current
Increase Root face
Train Welder
Train Welder
Overlap
Cause
1) Wrong Direction Of Arc
2) Inadequate Current
3) Excess Filler Wire
Overlap
Remedy
1) Train & Qualify Welder
2) Increase Current
3) Reduce Filler Metal
Suck Back*
Cause
1) Excess weaving in root
2) Excess Current
3) Inadequate root face
4) Wrong Electrode angle
Remedy
1) Reduce weaving
2) Reduce Current
3) Increase root face
4) Train / Qualify Welder
Suck Back
Under flush
Cause
Remedy
Under flush
Burn through*
Cause
1) Excess Current
2) Excess Root opening
3) Inadequate Root face
4) Improper weaving
Remedy
1) Reduce the Current
2) Reduce root opening
3) Increase root face
4) Train / Qualify Welder
Tungsten Inclusion
Cause
1) Ineffective HF
2) Improper Starting of Arc
3) Tungsten Tip Comes in
Contact With Weld
Tungsten Inclusion
Remedy
1) Rectify HF Unit
2) Never Touch Weld
With Tungsten Rod
3) Train / Qualify welder
Stray Arcing
Cause
Remedy
1) HF Not In Operation
1) Rectify HF Unit
2) Inadequate Skill of Welder 2) Train the Welder
Arc Strikes
Thanks