Gas Tungsten Arc Welding Process (GTAW)

Posted by Florida Gas Welding

-GTAW process can produce temperatures of up to 35,000. F. The GTAW torch brings heat only to the
workpiece.
-If filler metal is desired, it may be added manually like in oxy-acetylene welding or an automatic filler
metal feeding system can be utilized.
Some of these advantages are:
A. Highly concentrated arc:
This permits pinpoint control of heat allowing a narrow heat affected zone. A high concentration of heat is
an advantage when welding metals that possess high heat conductivity, such as aluminum and copper.
Because of the highly concentrated arc, some safety precautions should be observed:
1. Unprotected skin is quickly sunburned by the arc rays. Eyes should be properly protected by the
correct shade of lens.
Other workers in the area must be protected from stray glare or flash.
2. When welding in confined areas, such as inside tanks or containers, concentrations of ozone and
nitrous oxides can easily reach an unsafe level. Precautions must be taken to ventilate these areas
properly.
B. Inert gas shielding:
Inert means inactive or deficient in active chemical properties. The shielding gas serves only to blanket
the weld and exclude the active properties in the surrounding air. It does not burn, and adds nothing to or
takes anything from the metal. Inert gases like argon and helium do not chemically react or combine with
other gases. They possess no odor and are transparent permitting the operator maximum visibility of the
arc.
C. No flux or slag:
There is no requirement for flux with this process, therefore, there is no slag to obscure the operators
vision of the puddle. The finished weld will not have slag to remove between passes. Entrapment of slag
in multiple pass welds is not a problem.
D. No smoke or fumes:
The process itself does not produce smoke or injurious fumes. If the base metal contains coatings or
elements such as lead or zinc that produce fumes, these must be contended with as in any fusion welding
process on these materials. If the base metal contains oil, grease, paint or other contaminants, smoke and
fumes will definitely be produced as the heat of the arc burns them
away. The base material should be cleaned to make the conditions most desirable.
E. No sparks or spatter:
In the GTAW process there is no transfer of metal across the arc. There are no molten globules of spatter
to contend with and no sparks produced if the material being welded is free of contaminants. This is
advantageous where spatter would create a problem around the weld or on adjoining parts.
In summary, GTAW welding is a clean process. It is desirable from an operator point-of-view because of
the reasons outlined.
The operator must maintain good welding conditions by properly cleaning material, using clean filler metal,
clean welding gloves, and keep oil, dirt and other contaminants away from the weld area. Cleanliness
cannot be overemphasized, particularly on aluminum and magnesium. These metals are more susceptible
to contaminants than are ferrous metals. Porosity in aluminum welds has been shown to be caused by
hydrogen. Consequently, it is most important to eliminate any sources of hydrogen contamination such as
moisture and hydrocarbons

Defects/imperfections in welds - slag inclusions

Job Knowledge 43

Prevention of slag inclusions by grinding between runs

The characteristic features and principal causes of slag imperfections are described.

Identification

Fig. 1. Radiograph of a butt weld showing two slag lines in the weld root

Slag is normally seen as elongated lines either continuous or discontinuous along the length of the
weld. This is readily identified in a radiograph, Fig 1. Slag inclusions are usually associated with the
flux processes, ie MMA, FCA and submerged arc, but they can also occur in MIG welding.

Causes
As slag is the residue of the flux coating in MMA welding, it is principally a deoxidation product from
the reaction between the flux, air and surface oxide. The slag becomes trapped in the weld when two
adjacent weld beads are deposited with inadequate overlap and a void is formed. When the next layer
is deposited, the entrapped slag is not melted out. Slag may also become entrapped in cavities in

multi-pass welds through excessive undercut in the weld toe or the uneven surface profile of the
preceding weld runs, Fig 2.
As they both have an effect on the ease of slag removal, the risk of slag imperfections is influenced by

Type of flux coating

Welder technique

The type and configuration of the joint, welding position and access restrictions all have an influence
on the risk of slag imperfections.

Fig. 2. The influence of welder technique on the risk of slag inclusions when welding with a basic MMA (E7018)
electrode a) Poor (convex) weld bead profile resulted in pockets of slag being trapped between the weld runs

b) Smooth weld bead profile allows the slag to be readily removed between runs

Type of flux coating

One of the main functions of the flux coating in welding is to produce a slag which will flow freely over
the surface of the weld pool to protect it from oxidation. As the slag affects the handling characteristics
of the MMA electrode, its surface tension and freezing rate can be equally important properties. For
welding in the flat and horizontal/vertical positions, a relatively viscous slag is preferred as it will
produce a smooth weld bead profile, is less likely to be trapped and, on solidifying, is normally more

easily removed. For vertical welding, the slag must be more fluid to flow out to the weld pool surface
but have a higher surface tension to provide support to the weldpool and be fast freezing.
The composition of the flux coating also plays an important role in the risk of slag inclusions through
its effect on the weld bead shape and the ease with which the slag can be removed. A weld pool with
low oxygen content will have a high surface tension producing a convex weld bead with poor parent
metal wetting. Thus, an oxidising flux, containing for example iron oxide, produces a low surface
tension weld pool with a more concave weld bead profile, and promotes wetting into the parent metal.
High silicate flux produces a glass-like slag, often self detaching. Fluxes with a lime content produce an
adherent slag which is difficult to remove.
The ease of slag removal for the principal flux types are:

Rutile or acid fluxes - large amounts of titanium oxide (rutile) with some silicates. The oxygen
level of the weld pool is high enough to give flat or slightly convex weld bead. The fluidity of the
slag is determined by the calcium fluoride content. Fluoride-free coatings designed for welding in
the flat position produce smooth bead profiles and an easily removed slag. The more fluid fluoride
slag designed for positional welding is less easily removed.
Basic fluxes - the high proportion of calcium carbonate (limestone) and calcium fluoride
(fluospar) in the flux reduces the oxygen content of the weld pool and therefore its surface tension.
The slag is more fluid than that produced with the rutile coating. Fast freezing also assists welding
in the vertical and overhead positions but the slag coating is more difficult to remove.

Consequently, the risk of slag inclusions is significantly greater with basic fluxes due to the inherent
convex weld bead profile and the difficulty in removing the slag from the weld toes especially in multipass welds.

Welder technique
Welding technique has an important role to play in preventing slag inclusions. Electrode manipulation
should ensure adequate shape and degree of overlap of the weld beads to avoid forming pockets which
can trap the slag. Thus, the correct size of electrode for the joint preparation, the correct angle to the
workpiece for good penetration and a smooth weld bead profile are all essential to prevent slag
entrainment.
In multi-pass vertical welding, especially with basic electrodes, care must be taken to fuse out any
remaining minor slag pockets and minimise undercut. When using a weave, a slight dwell at the
extreme edges of the weave will assist sidewall fusion and produce a flatter weld bead profile.
Too high a current together with a high welding speed will also cause sidewall undercutting which
makes slag removal difficult.
It is crucial to remove all slag before depositing the next run. This can be done between runs by
grinding, light chipping or wire brushing. Cleaning tools must be identified for different materials eg
steels or stainless steels, and segregated.

When welding with difficult electrodes, in narrow vee butt joints or when the slag is trapped through
undercutting, it may be necessary to grind the surface of the weld between layers to ensure complete
slag removal.

Best practice
The following techniques can be used to prevent slag inclusions:

Use welding techniques to produce smooth weld beads and adequate inter-run fusion to avoid
forming pockets to trap the slag
Use the correct current and travel speed to avoid undercutting the sidewall which will make the
slag difficult to remove
Remove slag between runs paying particular attention to removing any slag trapped in crevices
Use grinding when welding difficult butt joints otherwise wire brushing or light chipping may be
sufficient to remove the slag.

Acceptance standards
Slag and flux inclusions are linear defects but because they do not have sharp edges compared with
cracks, they may be permitted by specific standards and codes. The limits in steel are specified in BE
EN ISO 5817: 2007 for three quality levels.
Article prepared by Bill Lucas with help from Gene Mathers and Colin Eileens.

The whats, whys, and whens of GTAW

WWW.THEFABRICATOR.COM NOVEMBER 2007
NOVEMBER 6, 2007

BY: JACK FULCER

More difficult to learn than some welding processes, gas tungsten arc welding
(GTAW) can be used to weld a greater range of materials than most other
processes. This article explains GTAW, examines its advantages and
disadvantages, describes appropriate and inappropriate applications, and
discusses how important cleanliness is in GTAW

If you are among those who want to learn about welding just for fun, or if you are considering a new
career, knowledge is always the key to success. Well, that and a little practice!
Gas tungsten arc welding (GTAW) is among the more difficult welding processes to learn, and just
like shielded metal arc welding (SMAW) or gas metal arc welding (GMAW), it has distinct advantages
and disadvantages (seeFigure 1). GTAW is suitable for certain applications and totally inappropriate
for others. To master GTAW, it is important to know these details before you begin.

GTAW

GTAW

Advantages

Disadvantages

Clean, high-quality
welds

Lower deposition rates

Welds a wide range

Requires high level of operator

of metals

skill

No spatter or slag,
sparks, or smoke
Allows for welding
in all positions

Higher level of UV rays

Requires good eye and hand
coordination to achieve quality
weld

Figure 1

What Is GTAW?
The GTAW process uses a nonconsumable electrodetungstento create an arc and transfer heat
(or, the current) to the base metal that is being welded. At the same time, an inert gas, usually argon

or an argon/helium mixture, shields the weld puddle from the atmosphere and protects the weld from
contamination.
Unlike SMAW or GMAW, GTAW does not require a consumable filler metal for every application;
however, when one is used, it is slowly fed into the weld pool by the hand opposite that holding the
torch. GTAW filler metals, often called rods or cut-lengths, are available in diameters ranging from
1/16 in. to in. They also are available in multiple compositions or specifications to meet the
chemical and mechanical properties of the base material being welded (see Figure 2).

Base Material

Common GTAW Filler

Metals

Carbon Steel

ER70S-6 or ER70S-3

Aluminum

ER4043 or ER5356

Stainless Steel

ER308, ER309, or ER316

Chrome-Molybdenum

ER80S-D2 or ER70S-2

Titanium

ERti-5ELI

Figure 2

Why Use GTAW?

Considering what GTAW is, the next logical question seems to be: Why use it?
First, it can be used to weld more materials than any other welding process, even exotic and heavieralloyed metals. Among those materials you can successfully use GTAW for (with practice!) are
stainless steel, aluminum, chrome-moly, nickel, and titanium. Of course, you also can weld plain old
carbon steel with GTAW.
Next, GTAW produces very clean and high-quality welds, making it a good choice for applications in
which aesthetics count or X-ray-quality welds are required. It also works well on thin materials, even
those measured by gauge as opposed to inches.
For example, you can weld material down to 30 gauge with GTAW, which makes it a good process for
computer housings, electronic components, and tubing. This is because the process allows for a
more direct, or concentrated, arc and produces a narrow heat-affected zone (HAZ) on the base
material. HAZ comprises the area surrounding the weld, which has not melted but has been altered
by the heat. By minimizing the HAZ, GTAW helps prevent distortion, particularly on thin materials.
Overall, the lower heat generated by the GTAW process also minimizes the chances of burn-through
on thin materials.

As a rule, GTAW does not produce sparks, spatter, or fumes, making it a relatively clean process. It
can be, and often is, completed in the comfort of an air-conditioned room, although proper ventilation
is always critical.
An important note: If the material being welded is dirty, then the previous rule may not apply. For that
reason, one of the oldest and most important adages about GTAW is clean and clean some more!
The base material you are welding should be cleaned either with a brush, cloth, or an appropriate
chemical compound to achieve the full GTAW advantage. If you are not certain of the best cleaning
method for the material you are welding, check with your local welding distributor.
Finally, another reason GTAW is often used is that it does not require a lot of postweld cleaning. For
example, you will not have to chip slag or grind spatter after welding. Note, however, that you may
have to, or simply want to, grind a gas tungsten arc weld for aesthetic reasons.

Appropriate Applications
All of this said, GTAW sounds great, right? Well, it isbut only under the right circumstances. Good
applications (especially for material less than in. thick) include:

Automotive work, including roll cages, frames, and exhausts

HVAC applications, including ductwork

Petrochemical and pipe applications

Metal artwork and ornamental applications

Maintenance and repair, including machine components and tools

Not the Fastest

If you have thicker materials (about in. or thicker) that can be welded using GMAW or SMAW, you
may want to consider these processes instead of GTAW, because they generally are faster. That is a
drawback of GTAW: It is a slow process.
For example, whereas the travel speed (the rate at which you weld) during GMAW is determined by
the rate at which the welding wire is being fed through the gun and the amperage at which you are
welding (among other factors), generally GTAW is only as fast as you are, or, more accurately, as fast
as you can feed the filler rod into the weld puddle. The GTAW process requires much practice and
skill to master, and even more of both to do it quickly and precisely.
Also, GTAW deposition rates are lower than SMAW's or GMAW's. Deposition rate is the amount of
filler metal that is deposited in a given amount of time. As an example, the average deposition rate for
a GMAW application using a solid welding wire is 8 to 9 lbs. per hour, but GTAW deposits only 2 to 3
lbs. per hour.

In short, GTAW probably won't be your first choice to weld thick materials quickly. It also should not
be your first choice for material that is rusty or has mill scale on it, as GTAW filler rods do not have the
added deoxidizers that allow many SMAW electrodes and GMAW welding wires to produce
successful welds under these conditions.
GTAW has its place, just like the other welding processes. It is neither superior to SMAW or GMAW,
nor is it inferior. Rather, it is more suitable for certain metals, material thicknesses, and environments.
If you are at all confused about when or how to use the GTAW process, or if you are ready to take
your skill to the next level, contact your local welding distributor or welding equipment manufacturer
for pointers. Often these groups have technical support teams whose advice can be invaluable. And
don't forget the importance of just a bit of practice too!