Tig Specifications

8/3/2019 Tig Specifications

1/8

TOLL FREE ORDER ENTRY

TEL: 1-800-426-0877

FAX: 1-800-327-5038

CK WORLDWIDE, INC.

P.O. BOX 1636

AUBURN, WA. 98071

USA

CUSTOMER SERVIC

TEL: 1-253-854-58

FAX: 1-253-939-17

TECHNICAL SPECIFICATIONSFOR TIG WELDING

FORM #116

WWW.CKWORLDWIDE.COM

July 2000

ORLDWIDE INC.


2/8

CK WORLDWIDE, INC. TEL:(253)-854-5820 FAX:(253)-939-1746 TOLL FREE TEL:800-426-0877

TECHNICAL SPECIFICATIONS MANUAL

TIG TORCH CO NNECTION DIAGRAMSGAS COOLED TORCHESWATER COOLED TORCHES

CHARACTERISTICS OF CURRENTTYPES FOR GAS TUNGSTEN ARC WELDINGDC STRAIGHT POLARITYDC REVERSE POLARITYAC HIGH FREQUENCY

SHIELD G AS SELECTION AND USESHIELD GAS SELECTOR CHARTGUIDE FOR SHIELD G AS FLOWS, CURRENT SETTINGS, C UP SELECTION

TUNGSTEN SELECTION AND PREPARATIONTUNGSTEN ELECTRODE SELECTOR CHARTTUNGSTEN PREPARATIONTUNGSTEN ELECTRODE TIP SHAPES AND C URRENT RANGES

TUNG STEN COLOR CODE AND PROPER TORCH USECOLOR CODE AND ALLOYING ELEMENTS FOR TUNG STEN ELECTRODE ALLOYSCORRECT TORCH AND ROD POSITIONINGSELECTING THE CORRECT TORCH NOZZLEGAS LENS BENEFITS

TYPICAL MANUAL GTA (TIG) WELDING PARAMETERS

ALUMINUMTITANIUMMAG NESIUMSTAINLESS STEELDEOXIDIZED COPPERLOW ALLOY STEEL

TROUBLE SHOOTING GUIDE FOR GTA (TIG) WELDINGEXCESSIVE ELECTRODE C ONSUMPTIONERRATIC ARCINCLUSION OF TUNGSTEN OR OXIDES IN WELD

POROSITY IN WELD DEPOSITCRACKING IN WELDSINADEQUATE SHIELDINGARC BLOWSHORT PARTS LIFE

222

2222

333

4444

55555

6

666666

7777

77777

THE INFORMATION IN THISMANUAL REPRESENTSTHE BESTJUDG EMENTOF C K WORLDWIDE, INC . AND IS INTENDED FOR USE BY EXPERIENC ED PERSONNEL. NEVER OPERATEANY EQUIPMENTWITHOUTCAREFULLY READING , UNDERSTANDING, AND FOLLOWING ALL OF THE RELATED SAFETY RULES AND PRACTICES. CK WORLDWIDE MAKES NOCLAIMS, EXPRESSED O R IMPLIED, AS TO THE VIABILITY OF THIS INFORMATION FOR ANY APPLICATION OR USE. THE INDIVIDUAL USER IS SOLELY RESPONSIBLE FOR ANY ANDALL USES OF THE INFORMATION C ONTAINED HEREIN, SINCE CK WORLDWIDE HAS NO MEANS TO C ONFIRM THE CORRECTUSE OF, OR CO NTROL ANY OF THE VARIABLES TOTHE USE OF ANY AND ALL INFORMATION HEREIN.

TABLE OF CONTENTS


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CK WORLDWIDE, INC. TEL:(253)-854-5820 FAX:(253)-939-1746 TOLL FREE TEL:800-426-0877 2FORM #116

TECHNICAL SPECIFICATIONS MANUA L TIG TORCH CONNECTIONS ANDPOLARITY CHARACTERISTICS

CONNECTION DIAGRAM FOR WATER COOLED TORCHES

1 PIECECABLE ASSEMBLY

2 PIECECABLE ASSEMBLY

CONNECTION DIAG RAMS FOR GAS COOLED TORCHES

When TIG welding, there are three choices of welding current. They are: Direct Current Straight Polarity, Direct Current Reverse Polarity, and A lternatingCurrent with H igh Frequency stabilization. Each of these has its applications, advantages, and disadvantages. A look at each type and its uses will help theoperator 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 configura-tion. The diagrams below, show arc characteristics of each current polarity type.

CHARACTERISTICS OF CURRENTTYPES FOR GAS TUNGSTEN ARC WELDING

TIG welding with DCSP (direct current straightpolarity) produces deep penetration because itconcentrates the heat in the joint area. Nocleaning action occurs with this polarity.

CURRENTTYPE DCSP

ELEC TROD EPOLARITY El ec t ro d e N eg a t ive

OXIDE CLEANING ACTION No

HEATBALANCEIN THEARC70%at work end

30%at electrode end

PENETRA TIO N PRO FILE De ep , na rro w

ELEC TRODE CAPAC ITY Exc elle nt

CURRENTTYPE DCRP

ELEC TROD EPOLARITY El ec t ro d e p o sit ive

OXIDE CLEANING ACTION Yes

HEATBALANCEIN THEARC30%at work end

70%at electrode end

PEN ETRA TI ON PRO FI LE Sh allo w , w id e

ELECTRODE CAPACITY Poor

CURRENTTYPE ACHF

ELEC TRO DE PO LARITY Alte rna ting

OXIDECLEANING ACTION Yes(once every half cycle)

HEATBALANCE IN THEARC50%at work end

50%at electrode end

PENETRATION PROFILE Med ium

ELECTRODECAPACITY Good

TIG welding with DCRP (direct current reversepolarity) produces good cleaning action as theargon ions f lowing towards the work str ike withsufficient force to break up oxides on the surface.

TIG welding with ACHF (alternating current highfrequency) combines the good weld penetrationon the negative half cycle with the desiredcleaning action of the positive half cycle. Highfrequency reestablishes the arc which breaks eachhalf cycle.

Shie ldga s

supply

Pow er Source

+-

+

-

ELECTRONS

IONS

DC TIG

POWER

SUPPLY

+

+

+-

-

-

-+

-

+

ELECTRONS

ION

S

DC TIG

POWER

SUPPLY

+

+

+-

-

-

+/-

+/-

ELECTRONS

ION

S

AC TIG

POWER

SUPPLY

+

+

+-

-

-

TIGTORCH

WA TEROUT

CoolantRec irc ulator

WA TER IN

ARGON IN

Regulator-Flowmeter

NO TE:

1 Quart (1 liter) per min. flow rate

Water in though w ate r line

Water out though power cab le

Powe r ca bleadapterrequired

Pow er Sourc e

Shie ldga s

supply

Pow er Source

Power cableadapterrequired Shie ld

ga ssupply

+

+

+


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CK WORLDWIDE, INC. TEL:(253)-854-5820 FAX:(253)-939-1746 TOLL FREE TEL:800-426-08773 FORM #116

TECHNICAL SPECIFICATIONS MANUALSHIELD G AS SELECTIO N

AND USE

For pure helium shielding gas, double flow rates shown. For argon-helium mixes with below 30% helium content, use figures shown. Always adjust gas f lows toaccommodate best shielding results.

BASE METALTYPE

THIC KNESSRANGE

WELD TYPE SHIELD GAS TYPE CHARACTERISTICS

ALUMINUMALLOYS AND

MAGNESIUM

ALLOYS

Thin Manual Pureargon Best arc star ts, cont rol of penet rat ion , cleaning and appeaerance on thin gauges.

Thick Manual 75 Ar - 25 He Increase heat input with good arc starts of argon, but with faster welding speeds.

General Purpose Manual Pureargon Best overall for good arc starts, control of penetration, cleaning and appearance.

Thin Mechanized 50 Ar - 50 He Higher weld speed under 3/4" thick, with good arc stabil ity and starting.

Thick Mechanized Purehelium Highest weld speeds, deeper penetration with DCSP, demanding arc starting and fixturing requirements, high flow rates needed.

COPPER ALLOYSCu-NI ALLOYSNICKEL ALLOYS

Thin M anual Pureargon Good control of weld puddle, bead contour , and penetraion on thin gauges.


General Purpose Manual 75 Ar - 25 He Increase heat input with good arc starts of argon, but with faster welding speeds.

Thin Mechanized 25 Ar - 75 He Higher weld speed under 3/4" thick, with good arc stabil ity and starting.

Thick Mechanized PureHelium Highest weld speeds, deeper penetration with DCSP, demanding arc starting and fixturing requirements, high flow rates needed.

LOW CARBON

ALLOYS ANDLOW ALLOY

STEELS

Thin Manual PureArgon Best arc star ts, cont rol of penet rat ion, cleaning and appearance on thin gauges.


General Purpose Manual Pureargon Best overall for good arc starts, control on penetration, cleaning and appearance.

Thin Mechanized Pureargon Best overall for good arc starts, control on penetrat ion, cleaning and appearance.

Thick Mechanized 75 Ar - 25 He Increase heat input with good arc starts of argon, but with faster welding speeds.

STAINLESS STEELSAND DUPLEX

ALLOYS

Thin ManualArgon under 1/ 16"

95 Ar- 5 H over 1/ 16"Argon with hydrogen added increases heat input and improves bead contour with lower gas flows, improves weld puddle wetting andminimizes undercutting.


General Purpose ManualArgon or

95 Ar - 5 HArgon or 95 Ar - 5 H can be used interchangably on austeritic stainless steel.

Thin Mechanized

Argon or

85 Ar - 15 H Argon provides stable arc control, 85 Ar - 15 H doubles argons welding speeds.

Thick Mechanized75 Ar - 25 Heor

65 Ar - 35 HIncrease heat input with good arc starts of argon, but with faster welding speeds.

TITANIUMALLOYS

Thi n Manual Pur eargon Argon's hi gh densi ty provides optimum shi elding and ar c stabi li ty.

Thick ManualArgon or

75 Ar - 25 HeArgon with helium addition adds penetration for manual welding of thick sections.

General Purpose Manual Pureargon Best overall for good arc starts, control of penetration, cleaning and appearance.

Thin Mechanized Pureargon Best arc starts, control of penetrat ion, cleaning and appearance on th in gauges.

Thick MechanizedArgon or

75 Ar - 25 HeArgon with helium increases penetration and welding speed for thick sections.

Thick Mechanized Pureargon Argon's h igh density provides needed shielding of exposed areas at back of weld.

SHIELD G AS SELECTOR CHART

GUIDE FOR SHIELD G AS FLOWS, CURRENTSETTINGS AND C UP SELECTION

ARGON FLOW

- ALUMINUM

ARGON FLOW

- FERROUS METALS

WELDING CURRENT (AMPS)

- TUNGSTEN TYPE

Gas LensBody

CFH (L/ MN)

StandardBody

CFH (L/ MN)

Gas LensBody

CFH (L/ MN)

StandardBody

CFH (L/ MN)

DCSPTho ria ted

DCSPPure

ACTho ria ted

ACPure

.020 (0.50)

.040 (1.00)

1/16 (1.60)

3/32 (2.40)

1/8 (3.20)

5/32 (4.00)

3/16 (4.80)

1/4 (6.40)

CupSize

Elec trod e

Diameterin inches

(mm)

5-8 (3-4)

5-10 (3-5)

7-12 (4-6)

10-15 (5-7)

10-20 (5-10)

12-25 (6-12)

15-30 (7-14)

25-45 (12-21)

5-8 (3-4)

5-12 (3-6)

8-15 (4-7)

10-20 (5-10)

12-25 (6-12)

15-30 (7-14)

25-40 (12-19)

30-55 (14-26)

5-8 (3-4)

5-8 (3-4)

5-10 (3-5)

8-10 (4-5)

8-12 (4-6)

12-25 (6-12)

20-35 (10-17)

10-15 (5-7)

5-8 (3-4)

5-10 (3-5)

7-12 (4-6)

10-15 (5-7)

10-18 (5-9)

15-25 (7-12)

20-35 (10-17)

25-50 (12-24)

5 - 20

20 - 80

80 - 150

150 - 250

240 - 350

400 - 500

475 - 800

700 - 1100

5 - 15

15 - 70

70 - 130

150 - 220

220 - 330

375 - 475

475 - 800

750 - 1000

5 - 20

15-80

70 - 150

140 - 235

220 - 325

300 - 425

400 - 525

500 - 700

5 - 15

10 - 60

50 - 100

100 - 160

150 - 210

200 - 275

250 - 350

325 - 700

3,4 or 5

4 or 5

4, 5 or 6

6, 7 or 8

7, 8 or 10

8 or 10

8 or 10

10


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TECHNICAL SPECIFICATIONS MANUA LTUNGSTEN SELECTION AND

PREPARATION

BASEMETAL TYPETHICKNESS

RANGEDESIRED RESULTS

WELDINGCURRENT

ELEC TRO DE TYPE SHIELD G AS TUNG STEN PERFO RM ANC E CHA RA CTERISTIC S

ALUMINUMALLOYS ANDMA GNESIUM

ALLOYS

All General Purpose ACHF

Pure (EW-P) ArgonBalls easily, low cost, tends to spit at higher currents, used for non-c ritical w elds

only.

Zirco niated(EW-Zr)

ArgonBalls well, takes higher c urrent, w ith less spitting a nd with b etter arc starts and arcstability than pure tungsten.

2% Thoriat ed(EW-Th2)

75 Argon25 Helium

Higher current range and stability, better arc starts, with lower tendency to spit,med ium erosion.

Only thin

sectionsControl penetration DCRP

2% Ceriated

(EW-Ce2)

Argon

Helium

Lowe st erosion rate , widest current range , AC or DC, no spitting, best arc starts

and stability.

Only thicksections

Increase penetration or travelspeed

DCSP

2% Thoriat ed

(EW-Th2)

75 Argon

25 Helium

Best stability at med ium currents, good arc starts, medium te ndenc y to spit,

med ium erosion rate.

2% Ceriated(EW-Ce2)

HeliumLow erosion rate , wide c urrent range, AC or DC, no spitting, co nsistent arc starts,good stability.

CO PPERALLOYS,Cu- Nl ALLOYS

AND NICKELALLOYS

All General Purpose DCSP


75 Argon25 Helium

Best stability at med ium currents, good arc starts, medium te ndenc y to spit,med ium erosion rate.

2% Ceriated

(EW-Ce2)

75 Argon

25 Helium

Low erosion rate , wide c urrent range, AC or DC, no spitting, co nsistent arc starts,

good stability.

Only thinsections

Control penetration ACHFZirco niated

(EW-Zr)Argon Use on lower currents only, spitting on starts, rapid erosion rates at higher currents.

Only thicksections

Increase penetration or travelspeed

DCSP2% Ceriated

(EW-Ce2)75 Argon25 Helium

Low erosion rate , wide c urrent range, AC or DC, no spitting, co nsistent arc starts,good stability.

MILD STEELS,

CARBON STEELSALLOY STEELS

STAINLESSSTEELS

AN D TITANIUMALLOYS

All General Purpose DCSP


75 Argon25 Helium

Best stability at med ium currents, good arc starts, medium te ndenc y to spit,med ium erosion rate.

2% Ceriated

(EW-Ce2)

75 Argon

25 Helium

Low erosion rate , wide c urrent range, AC or DC, no spitting, co nsistent arc starts,

good stability.

2% Lantha nate d(EWG-La2)

75 Argon25 Helium

Lowe st erosion rate , widest current range on DC, no spitting, best DC arc startsand stability.

Only thinsections

Control penetration ACHFZirco niated

(EW-Zr)Argon Use on lower currents only, spitting on starts, rapid erosion rates at higher currents

Only thick

sections

Increase penetration or travel

speedDCSP

2% Ceriated

(EW-Ce2)

75 Argon

25 Helium

Low erosion rate , wide c urrent rang e, no spitting, consistent a rc starts, good

stability.

2% Lantha nate d(EWG-La2)

HeliumLowe st e rosion rate, highe st c urrent ran ge, no spitting, best DC arc starts andstability.

TUNGSTEN ELECTRODE SELECTOR CHART

TUNGSTEN EXTENSION

STANDA RD PARTSGeneralpurpose

3 X DIA.

GAS LENS PARTSGeneralPurpose3 X DIA.

MAX:6 X DIA.

(IN DRAFT-FREE AREAS)

TUNG STEN GRINDING

Shape by grinding longitudinally (never radially).Remove the sharp point to leave a truncated point with

a f lat spot. Diameter of f lat spot determines amperage

capacity. (See below)

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

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

DCSP (EN) OR DC RP (EP)

General Purpose FLAT: 1/ 4 TO1/2 X DIA.

2-3 DIA.Taper length

ACHFGeneral Purpose MAX.

BALL1 X DIA.

Ball tip by arcing on clean metal at low current DCRP(EP) then slowly increasecurrent to form thedesired balldiameter. Return setting to AC.

TUNGSTEN TIP PREPARATIO N

ELECTRODEDIAMETERMM IN

DIAMETER ATTIPMM IN

CONSTANTINCLUDEDANGLE, DEGREES

CURRENTRANGEA

PULSED CURRENTRANGEA

1.0 .040 .125 .005 12 2-15 2-25

1.0 .040 .250 .010 20 5-30 5-60

1.6 1/16 .500 .020 25 8-50 8-100

1.6 1/16 .800 .030 30 10-70 10-140

2.3 3/32 .800 .030 35 12-90 12-180

2.3 3/32 1.100 .045 45 15-150 15-250

3.2 1/8 1.100 .045 60 20-200 20-300

3.2 1/8 1.500 .060 90 25-250 25-350

TUNGSTEN ELECTRODE TIP SHAPES AND CURRENTRANGES

Thoriated, ceriated, and lanthanated tungsten electrodes do not ball as readily as pure or zirconiated tungsten electrodes, and as such are typically usedfor DCSP welding. These electrodes maintain a ground tip shape much better than the pure tungsten electrodes. If used on AC, thoriated andlanthanated electrodes often spit. Regardless of the electrode tip geometry selected, it is important that a consistent tip configuration be used once awelding procedure is established. Changes in electrode geometry can have a significant inf luence not only on the weld bead width, depth of penetra-

tion, and resultant quality, but also on the electrical characteristics of the arc. Below is a guide for electrode tip preparation for a range of sizes withrecommended current ranges.


6/8

60 - 75

15 - 20

Nozzle

Direc tion of Travel

Welding Rod

Shield Gas

Tungsten Electrode

Vertical


TECHNICAL SPECIFICATIONS MANUAL

AWS

CLASSIFICATIONSCOLOR*

ALLOYING

ELEMENT

ALLOYING

OXIDE

NOMINAL WEIGHTOF

ALLOYING OXIDE PERCENT

EWP Green - - -

EWCe-2 Ora ng e Cerium CeO2 2

EWLa-1 Black Lanthanum La 2O3 1EWTh-1 Yellow Thorium ThO2 1

EWTh-2 Red Thorium ThO2 2

EWZr-1 Brown Zirconium ZrO2 .25

EWG Gray Not Spec ified** - -

COLOR CODE AND A LLOYING ELEMENTS FOR VARIOUS TUNG STEN ELECTRODE ALLOYS

*Color ma y be ap plied in the form of ba nds, do ts, etc., at any p oint on the surfac e of the elec trod e.**Ma nufacturers m ust identify the type and nom inal content of the rare ea rth oxide a dd itions.

CORRECTTORCH AND ROD POSITIONING

The sugge sted electrode and welding rod a nglesfor welding a bea d on p late. The sam e ang lesare used when ma king a butt w eld. The to rch isheld 60 - 75 from the m etal surfac e. This is thesame as holding the torch 15 - 30 from thevertical.

Take spe cial no te tha t the rod is in the shieldinggas during the welding process.

SELECTING THE CORRECTTORCH NOZZLE GAS LENS BENEFITS

Most nozzles used fo r GTAW are ma nufa ctu red fromceram ic mate rials, alumina (pink colored) and lava(white co lored). The e xit d iameter (diam eter c losest to

the a rc) is ma nufac tured in a variety o f sizes. GTAWnozzles are also ma de in va rious leng ths from shortnozzles to e xtra-long nozzles.

Alumina nozles are the most commonly used nozzles in

GTAW. Alumina nozzles are mo lde d from a luminaoxide and the density of the a lumina oxide d eterminesthe q uality of the nozzle in relationship to imp actresistance and thermal shock. Alumina nozzles aremore inp ac t resistan t than la va nozzles. The impa ct

resistanc e o f the alumina no zzles makes them m oredurable and are used fo r general app lications.

Ceram ic (lava) cups are recomm end fo r use in

app lications where high reflective heat is present.Alumina nozzles tend to b reak when used in confinedareas or when high reflective heat is present. If this

type of usage is contemplated , we recommend theuse o f c eramic (lava) c ups. When a lumina nozzles are

fired in the ove n at 3000F during manufac turing, theyshrink 18% in leng th a nd 27% in diame ter. If the nozzle issubsequently used in a c onfined a rea, excessive heatis transferred back into the nozzle causing it to expand.

Coo ling shrinks the no zzle ba ck to no rmal. The larg edifference be twee n expansion and c ontraction resultsin breakage.

The e xit diame ter fo r any no zzle is spec ified with a

number tha t represents the diameter in 1/16 (1.6mm)increm ents. A number 5 nozzle is theref ore 5/ 16 insidediamete r. A number 6 nozzle is 3/8 or 6/16 and so on.

The diame ter for any nozzle must be large eno ugh to

allow the entire weld area to be covered by theshielding ga s. The exit diame ter can b e neither toolarge nor too small, or poor shield ga s coverag e willresult. (Refer to pag e 3 fo r correct cup size.)

A collet bo dy with a g as lens ca n be very useful to a welde r.The purpo se o f a ga s lens is to ma ke the shielding g as exit thenozzle as a column instead of as a turbulent stream of gasthat be gins to spread out a fter exiting. The c olumn of ga sallow s the elec trode to stick out farther fo r visibility, allowingfor better access to the weld area, and a reduction in gasflow (CFH/ L/ Min).

TUNGSTEN COLOR CODE ANDPROPER TORCH USE

60 - 75

15 - 30

Design Diam eterto fit

GTAW torch

Exitdiameterm easured

in 1/16


7/8


TECHNICAL SPECIFICATIONS MANUA LTYPICAL MANUAL GTA (TIG)

WELDING PARAMETERS

METALGUAGEJOINTTYPE

TUNGSTEN SIZE FILLERROD SIZE CUP SIZE

SHIELD GA SFLOWWELDINGAMPERES

TRAVELSPEEDTYPE

CFH(L/MN)

PSI

1/ 16 (1.6 mm)

BUTT

1/ 16 (1.6 mm) 1/ 16 (1.6 mm) 4, 5, 6 ARGON 11 (5.5) 20

80-10012

(307.2 mm)

FILLET 90-10010

(256 mm)

1/8 (3.2 mm)

BUTT

1/ 16 (1.6 mm) 3/ 32 (2.4 mm) 4, 5, 6 ARGON 11 (5.5) 20

120-14012

(307.2 mm)

FILLET 130-15010

(256 mm)

3/ 16 (4.8 mm)

BUTT 3/32 (2.4 mm)

1/ 8 (3.2 mm) 5, 6, 7 ARGON 13 (6) 20

200-25012

(307.2 mm)

FILLET3/ 32 (2.4 mm)-1/ 8 (3.2 mm)

225-27510

(256 mm)

1/4 (6.4 mm)

BUTT

1/ 8 (3.2 mm) 3/ 16 (4.8 mm) 8, 10 ARGON 13 (6) 20

275-35010

(256 mm)

FILLET 300-3758

(204.8 mm)

STAINLESS STEEL (DCSP)

WELDING STAINLESS STEEL

In TIG welding of stainless steel, welding rods having the AWS-ASTM prefixes of E or ER can be usedas filler rods. However, only bare uncoated rods should be used. Stainless steel can be welded usingACHF, however, recommendations for DCSP must be increased 25%. Light gauge metals less then 1/

16 thick should always be welded with DCSP using argon gas. Follow the normal precautions forwelding 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 withother metals.

METALGUAGEJOINTTYPE

TUNGSTEN SIZE FILLERROD SIZE CUPSIZE

SHIELD GA SFLOWWELDINGAMPERES

TRAVELSPEEDTYPE

CFH(L/MN)

PSI

1/ 16 (1.6 mm)

BUTT

1/ 16 (1.6 mm) 1/ 16 (1.6 mm) 4, 5, 6 ARGON 15 (7) 20

95-13515

(384 mm)

FILLET 95-13515

(384 mm)

1/8 (3.2 mm)

BUTT

1/ 16 (1.6 mm)-3/ 32 (2.4 mm)- 3/ 32 (2.4 mm) 4, 5, 6 ARGON 15 (7) 20

145-20511

(281.6 mm)

FILLET 145-20511

(281.6 mm)

3/ 16 (4.8 mm)

BUTT

3/ 32 (2.4 mm) 1/ 8 (3.2 mm) 7, 8 ARGON 16 (6.5) 20

210-26010

(256 mm)

FILLET 210-26010

(256 mm)

1/4 (6.4 mm)

BUTT

1/ 8 (3.2 mm) 5/ 32 (4.0 mm) 8, 10 ARGON 18 (8.5) 20

240-30010

(256 mm)

FILLET (2) 240-30010

(256 mm)

LOW A LLOY STEEL (DC SP)

WELDI NG LOW ALLOY STEELMild and low carbon steels with l ess then 0.30% carbon and less than 1 thick, generally do notrequire preheat. An exception to this allowance is welding on highly restrained joints. These jointsshould be preheated 50 to 100F to minimize shrinkage cracks in the base metal. Low alloy steels suchas the chromium-molybdenum steels will have hard heat affected zones after welding, if the preheattemperature is too low. This is caused by rapid cooling of the base material and the formation ofmartensitic grain structures. A 200 to 400F preheat temperature will slow the cooling rate andprevent the martensitic structure.

METALGUAGEJOINTTYPE

TUNGSTEN SIZE FILLERROD SIZE CUPSIZE

SHIELD GA SFLOWWELDINGAM PERES

TRAV ELSPEEDTYPE

CFH(L/MN)

PSI

1/ 16 (1.6 mm)

BUTT

1/ 16 (1.6 mm) 1/ 16 (1.6 mm) 4, 5, 6 ARGON 18 (9) 15

110-14012

(307.2 mm)

FILLET 130-15010

(256 mm)

1/ 8 (3.2 mm)

BUTT

3/ 32 (2.4 mm) 3/ 32 (2.4 mm) 4, 5, 6 ARGON 18 (9) 15

175-22511

(258.6 mm)

FILLET 200-2509

(230.4 mm)

3/ 16 (4.8 mm)

BUTT

1/ 8 (3.2 mm) 1/ 8 (3.2 mm) 8, 10 HELIUM 36 (17.5) 15

190-22510

(256 mm)

FILLET 205-2508

(204.8 mm)

1/ 4 (6.4 mm)

BUTT(2)

3/ 16 (4.8 mm) 1/ 8 (3.2 mm) 8, 10 HELIUM 36 (17.5) 15

225-2609

(230.4 mm)

FILLET 250-2807

(179.2 mm)

DEOXIDIZED COPPER (DCSP)

WELDING DEOXIDI ZED COPPERWhere extensive welding is to be done, the use of deoxidized (oxygen-free) copper is preferable overelectrolytic tough pitch copper, although TIG welding has been used occasionally to weld zinc-bearingcopper alloys, such as brass and commercial bronzes, it is not recommended because the shielding gasdoes not suppress the vaporization of zinc. For the same reason zinc bearing fi ller rods should not beused. There is some preference of helium for the inert atmosphere in welding thickness above 1/8because of the improved weld metal fluidity. Preheating recommendations should be followed.

METALGUAGEJOINTTYPE



TRAVELSPEEDTYPE

CFH(L/MN)

PSI

1/ 16 (1.6 mm)

BUTT

1/ 16 (1.6 mm) NONE 4, 5, 6 ARGON 15 (7) 20

90-11010

(256 mm)

FILLET 110-1508

(204.8 mm)

1/ 8 (3.2 mm)

BUTT

3/ 32 (2.4 mm) 1/ 16 (1.6 mm) 5, 6, 7 ARGON 15 (7) 20

190-2209

(230.4 mm)

FILLET 210-250 7(179.2 mm)

3/ 16 (4.8 mm)

BUTT

3/ 32 (2.4 mm) 1/ 8 (3.2 mm) 6, 7, 8 ARGON 20 (10) 20

220-2508

(204.8 mm)

FILLET 240-2807

(179.2 mm)

1/ 4 (6.4 mm)

BUTT (2)

1/ 8 (3.2 mm) 1/ 8 (3.2 mm) 8, 10 ARGON 30 (15) 20

275-3108

(204.8 mm)

FILLET (2) 290-3407

(179.2 mm)

TITANIUM (DCSP)

WELDING TI TANIUMSmall amounts of impurities, particularity oxygen and nitrogen, cause embrittlement of molten or hottitanium. The molten weld metal in the heat-affected zones must be shielded by a protective blanket ofinert gases. Titanium requires a strong, positive pressure of argon or helium as a backup on the rootside of the weld, as well as long, trailing, protective tail of argon gas to protect the metal while cooling.Purge chambers and trailing shields are available from CK Worldwide to assist in providing qualityresults.

METALG UAGEJOINTTYPE



TRAVELSPEEDTYPE

CFH(L/MN)

PSI

1/ 16 (1.6 mm)BUTT

1/ 16 (1.6 mm)3/32 (2.4 mm)-

1/ 8 (3.2 mm)5, 6 ARGON 13 (5) 15

60 20

(512 mm)FILLET 60

1/ 8 (3.2 mm)BUTT

3/ 32 (2.4 mm)1/8 (3.2 mm)-5/ 32 (4.0 mm)

7, 8 ARGON 19 (9) 15115 17

(435.2 mm)FILLET 115

1/ 4 (6.4 mm)

BUTT

3/ 16 (4.8 mm) 5/ 32 (4.0 mm) 8 ARGON 25 (12) 15

100-13022

(563.2 mm)

BUTT(2)

110-13520

(512 mm)

1/ 2 (12.8 mm)BUTT

(2)1/ 4 (6.4 mm) 3/ 16 (4.8 mm) 10 ARGON 35 (17) 15 260

10(256 mm)

MAGNESIUM (ACHF)

WELDI NG MAGNESIUMMagnesium alloys are in three groups, they are: (1) aluminum-zinc-magnesium, (2) aluminum-magnesium, and (3) maganese-magnesium. Since magnesium absorbs a number of harmful ingredientsand oxiodize rapidly when subjected to welding heat, TIG welding in an inert gas atmosphere isdistinctly advantageous, the welding of magnesium is similar, in many respects, to the welding of

aluminum. Magnesium was one of the fir st metals to be welded commercially by TIG. Magnesiumrequires a positive pressure of argon as a backup on the root side of the weld.

METALGUAGEJOINTTYPE



TRAV ELSPEEDTYPE

CFH(L/MN)

PSI

1/16 (1.6 mm)

BUTT

1/ 16 (1.6 mm) 1/ 16 (1.6 mm) 4, 5, 6 ARGON 15 (7) 20

60-8012

(307.2 mm)

FILLET 70-9010

(256 mm)

1/ 8 (3.2 mm)

BUTT

3/32 (2.4 mm)

3/32 (2.4 mm)-1/8 (3.2 mm)

6, 7 ARGON 17 (8) 20

125-14512

(307.2 mm)

FILLET3/32 (2.4 mm)-1/ 16 (1.6 mm)

140-16010

(256 mm)

3/16 (4.8 mm)

BUTT

1/ 8 (3.2 mm) 1/ 8 (3.2 mm) 7, 8ARGON/HELIUM

21 (10) 20

190-22011

(258.6 mm)

FILLET 210-2409

(230.4 mm)

1/ 4 (6.4 mm)

BUTT

3/ 16 (4.8 mm) 1/ 8 (3.2 mm) 8, 10ARGON/HELIUM

25 (12) 20

260-30010

(256 mm)

FILLET 280-3208

(204.8 mm)

ALUMINIUM (ACHF)

WELDING ALUMI NUMThe use of TIG welding for aluminum 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 bedry, f ree of oxides, grease, or other foreign matter. I f f il ler metal becomes damp, heat for 2 hours at250F before using. Al though ACHF is recommended, DCRP has been successful up to 3/ 32 , DCSPwith helium shield gas is successful in mechanized applications.


8/8


TECHNICAL SPECIFICATIONS MANUALTROUBLE SHOOTING GUIDE FOR

GTA (TIG) WELDING

PROBLEM CAUSE SOLUTION

EXCESSIVEELECTRODE

CONSUMTION

1. Inadequategasflow.

2. Improper sizeelectrodefor current required.3. Operatingof reversepolatiy.4. Electrodecontamination.

5. Excessiveheatinginsidetorch.6. Electrodeoxidizingduringcooling.

7. Shield gasincorrect.

1. Increasegasflow.

2. Uselarger electrode.3. Uselarger electrodeor changepolarity.4. Removecontaminated portion, then prepareagain.

5. Replacecollet, try wedgecollet or reversecollet.6. Increasegaspost flow timeto 1 sec. per 10 amps.

7. Changeto proper gas(no oxygen or Co2).

ERRATIC ARC

1. Incorrect voltage(arc too long).2. Current too low for electrodesize.3. Electrodecontaminated.

4. Joint too narrow.5. Contaminated shield gas, dark stains on theelectrodeor weld bead indicatecontamination.

6. Basemetal isoxidized, dirty or oily.

1. Maintain short arc length.2. Usesmaller electrodeor increasecurrent.3. Removecontaminated portion, then prepareagain.

4. Open joint groove.5. Themost common causeis moistureor aspirated air in gasstream. Useweldinggradegasonly.Find thesourceof thecontamination and eliminateit promptly.

6. Useappropriatechemical cleaners, wirebrush, or abrasivesprior to welding.

INCLUSION OFTUNGSTEN OR

OXIDESINWELD

1. Poor scratch startingtechnique..2. Excessivecurrent for tungsten sizeused.3. Accidental contact of electrodewith puddle.

4. Accidental contact of electrodeto filler rod.5. Usingexcessiveelectrodeextension.

6. Inadequateshielding or excessivedrafts.7. Wronggas.

8. Heavy surfaceoxidesnot beingremoved.

1. Many codesdo not allow scratch starts. Usecopper strikeplate. Usehigh frequency arc starter.2. Reducethecurrent or uselarger electrode.3. Maintain proper arc length.

4. Maintain a distancebetween electrodeand filler metal.5. Reducetheelectrodeextension to recommended limits.

6. Increasegasflow, shield arc from wind, or usegaslens.7. Do not useAr-02 or Ar-Co2 GMA (MIG) gasesfor TIG welding.

8. UseACHF, adjust balancecontrol for maximum cleaning, or wirebrush and clean theweldjoint prior to welding.

POROSITY IN

WELD DEPOSIT

1. Entrapped impurities, hydrogen, air, nitrogen, water vapor.

2. Defectivegashoseor loseconnection.3. Filler material isdamp (particulary aluminum).

4. Filler material isoily or dusty.5. Alloy impuritiesin thebasemetal such assulpher, phosporus, lead and zinc.

6. Excessivetravel speed with rapid freezingof weld trappinggasesbeforethey escape.7. Contaminated shield gas.

1. Do not weld on wet material. Removecondensation from linewith adequategaspre-flow time.

2. Check hosesand connectionsfor leaks.3. Dry filler metal in oven prior to welding.

4. Replacefiller metal.5. Changeto a different alloy composition which isweldable. Theseimpuritiescan causeatendency to crack when hot.

6. Lower the travel speed.7. Replacetheshieldinggas.

CRACKING INWELDS

1. Hot cracking in heavy section or with metalswhich arehot shorts.

2. Crater cracksdueto improperly breakingthearc or terminatingtheweld at thejoint edge.

3. Post weld cold cracking, dueto excessivejoint restraint, rapid cooling, or hydrogen

embrittlement.4. Centerlinecracksin singlepasswelds.

5. Underbead cracking from brittlemicrostructure.

1. Preheat, increaseweld bead cross-section size, changeweld bead contour. Usemetal with feweralloy impurities.2. Reversedirection and weld back into previous weld at edge. UseAmptrak or foot control tomanually down slopecurrent.3. Preheat prior to welding, usepureor non-contaminated gas. Increasethebead size. Prevent

craters or notches, Changetheweld joint design.4. Increasebead size. Decreaseroot opening, usepreheat, prevent craters.

5. Eliminatesourcesof hydrogen, joint restraint, and usepreheat.

INADEQUATESHIELDING

1. Gasflow blockageor leak in hosesor torch.2. Excessivetravel speed exposesmolten weld to atmospheric contamination.

3. Wind or drafts.4. Excessiveelectrodestickout.5. Excessiveturbulencein gasstream.

1. Locateand eliminatetheblockageor leak.2. Useslower travel speed or carefully increasetheflow rateto asafelevel below creatingexcessiveturbulence. Useatrailingshield cup.

3. Set up screensaround theweld area.4. Reduceelectrodestickout. Usea larger sizecup5. Changeto gassaver parts or gaslensparts.

ARC BLOW1. Induced magnetic field from DC weld current.2. Arc isunstabledueto magnetic influences.

1. Changeto ACHF current. Rearangethesplit ground connection.2. Reduceweld current and usearc length asshort aspossible.

SHORTPARTSLIFE

1. Short water cooled leadslife.2. Cup Shatteringor cracking in use3. Short collet life.4. Short torch head life.

5. Gashosesballooning, bursting, or blowingoff whilehot.

1. Verify coolent flow direction, return flow must beon thepower cablelead.2. Changecup sizeor type, changetungsten position, refer to chart.3. Ordinary styleis split and twistsor jams. changeto wedgestyle.4. Do not operatebeyond rated capacity, usewater cooled model, do not bend rigid torches.

5. Incorrect flowmeter, TIG flowmetersoperateat 35 psi with low flows. MIG flowmetersoperatewith high flowsat 65 psi of more.

TROUBLE SHOOTING GUIDE

TOLL FREE ORDER ENTRY

TEL: 1-800-426-0877

FAX: 1-800-327-5038

CK WORLDWIDE, INC.

P.O. BOX 1636

AUBURN, WA. 98071USA

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TEL: 1-253-854-5820

FAX: 1-253-939-1746

WWW.CKWORLDWIDE.COM

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