WLD 222

Gas Tungsten Arc Welding

Aluminum
 INDEX

Syllabus 3-10

Information Sheets
• Introduction to GTAW 11-17
• Power Sources 18-30
• Welding Torch 31
• Tungsten Electrodes 32-34
• Shielding Gas 35
• Filler Material 36

Math on Metal 37-46

Chart Reading for Welders 47

Science on Aluminum 48-52

Welding Vocabulary Worksheets 53-55

GTAW Equipment & Consumables Worksheets 56-57

GTAW Aluminum Information Sheets 58-62

Craftsmanship Expectations for Welding Projects 63

Welding Projects 64-95

Final Exam Information 96-97

Grading Rubric for the Practical Exam 98

Assessment Breakdown for the Course 99

This project was supported, in part,

By the
National Science Foundation
Opinions expressed are those of the authors
And not necessarily those of the Foundation

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PCC/ CCOG / WLD
Course Number:
WLD 222

Course Title:
Gas Tungsten Arc Welding: Aluminum

Credit Hours:
4

Lecture Hours:
0

Lecture/Lab Hours:
80

Lab Hours:
0

Special Fee:
$24.00

Course Description
Develops knowledge and skills required to weld common joints in all positions on aluminum
using the gas tungsten arc welding (GTAW) process. Prerequisites: Department permission
required. Audit available.

Addendum to Course Description

This is an outcome based course utilizing a lecture/lab format. This course includes classroom
discussions, videotapes, and lab demonstrations of technical skills. Course outcomes will include:
theoretical concepts, layout, fabrication, welding and safety.

Intended Outcomes for the course

Upon completion of the course students should be able to:
• Function safely in the PCC Welding Lab.
• Interpret blueprints to accurately lay out, prepare and assemble weld joints.
• Understand and apply fundamentals of GTAW operations on aluminum.
• Weld common joints assemblies with gas tungsten arc welding to AWS D1.1 Structural Steel
Welding Code visual acceptance criteria in all positions.
• Apply visual examination principles and practices in accordance with AWS D1.1.

Course Activities and Design

Welding lec/lab courses are Open -Entry and Open Exit (OE/OE) and are offered concurrently. Courses
are designed to meet the needs of the student with flexible scheduling options. Students may attend full
time or part time. This is an OE/OE course which does not align with the normal academic calendar.

Outcome Assessment Strategies

The student will be assessed on his/her ability to demonstrate the development of course outcomes. The
methods of assessment may include one or more of the following: oral or written examinations, quizzes,
written assignments, visual inspection,welding tests and task performance.

Course Content (Themes, Concepts, Issues and Skills)

Function safely in the PCC Welding Shop.
• Understand and practice personal safety by using proper protective gear
• Understand and practice hand and power tool safety
• Understand and maintain a safe work area
• Recognize and report dangerous electrical and air/gas hose connections
• Understand and practice fire prevention
Interpret drawing and symbols to accurately lay out, prepare and assemble weld joints on aluminum.
• Interpret lines, symbols, views and notes
• Lay out material per drawing specifications
• Assemble project per specification
Understand and apply fundamentals of GTAW operations on aluminum.
• Describe and demonstrate equipment setup, shut down and operation
• Identify electrode types and preparation
• Demonstrate proper arc length and travel speed
• Demonstrate correct starting, stopping and restarting techniques
• Demonstrate proper bead placement
Weld common joints with the Gas Tungsten Arc Welding (GTAW) to AWS code quality visual
acceptance criteria in the following joints and positions.
Demonstrate correct welding techniques on the following joints:
Flat Position:
• Fuse weld a flat position edge joint
• Fuse weld a flat position corner joint
o Bead Plate
o T-Joint
o Butt Joint
Horizontal Position:
• T-Joint
• Lap Joint
• Outside Corner Joint
• Butt Joint
Vertical Position:
• T-Joint
• Lap Joint
• Outside Corner Joint
• Butt Joint
Over head Position:
 •
T-Joint
•
Lap Joint
•
Outside Corner Joint
Demonstrate visual examination principles and practices in accordance with AWS D1.1
Evaluate welds using appropriate welding inspection tools
Assess weld discontinuities causes and corrections

 Course Assignments
Required text book and Reading:
Welding Principles and Applications, By Larry Jeffus
Chapter 15, Gas Tungsten Arc Welding Equipment, Setup, Operation and Filler Metals
Chapter 16, Gas Tungsten Arc Welding of Plate

Information Sheets:
Introduction to GTAW Filler Material
Power Sources Set up procedures
Welding Torch Craftsmanship expectations
Tungsten Electrodes Visual inspection
Shielding Gas

Video Training: Writing Work Sheets:

“Gas Tungsten Arc Welding” by Miller Power Sources
GTAW 1,2,and 3 of the Miller Modular series Welding Torch
Bergwall GTAW video series (4 videos) Tungsten Electrodes
Shielding Gas

Welding Projects:
Flat Position Horizontal Position Vertical Position Overhead Position
(1F or 1G) (2F or 2G) (3F or 3G) (4F or 4G)
Edge Joint T-Joint T-Joint T-Joint
Corner Joint Lap Joint Lap Joint Lap Joint
Bead Plate Corner Joint Corner Joint Butt Joint
T-Joint Butt Joint Butt Joint

Timeline:
Open-entry, open-exit instructional format allows the students to work their own pace. It is the
student’s responsibility to complete all assignments in a timely manner. See your instructor
for assistance.

Outcome Assessment Policy:

The student will be assessed on his/her ability to demonstrate the achievement of course
outcomes. The methods of assessment may include one or more of the following: oral or written
examinations, quizzes, written assignments, visual inspection techniques, welding tests, safe
work habits, task performance and work relations.

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Grading Criteria
The student's assessment will be based on the following criteria:
20% of grade is based on Safe work habits and shop practices.
20% of grade is based on Completion of written and reading assignments.
20% of grade is based on demonstrating professional work ethics.
40% of grade is based on completion of welding exercises.

Grading Scale
90 - 100% A – Superior
Honor grade indicating excellence. Earned as a result of a combination of some or
all of the following as outlined in the course training packet. Superior examination
scores, consistently accurate and prompt completion of assignments, ability of to
deal resourcefully with abstract deas, superior mastery of pertinent skills, and
excellence attendance. Probable success in a field relating to the subject or
probable continued success in sequential courses.

80 - 89% B - Above average

Honor grade indicating competence. Earned as a result of a combination of some
or all of the following as outlined in the course training packet. High examination
scores, accurate and prompt completion of assignments, ability to deal with
abstract ideas, commendable mastery of pertinent skills and excellent attendance.
Probable continued success in sequential courses.

70 - 79% C – Average
Standard college grade indicating successful performance earned as a result of a
combination of some or all of the following as outlined in the course training
packet. Satisfactory examination scores, generally accurate and prompt
completion of assignments, ability to deal with abstract ideas, fair mastery of
pertinent skills and regular attendance. Sufficient evidence of ability to warrant
entering sequential courses.

60 - 69% D – Substandard
Substandard but receiving college credit. Substandard grade indicating that the
student has met only minimum requirements as outlined in the course training
packet. Earned as a result of some or all of the following: low examination
scores, generally inaccurate, incomplete or late assignments, inadequate grasp of
abstract ideas, barely acceptable mastery of pertinent skills, irregular attendance,
insufficient evidence of ability to make advisable the enrollment in sequential
courses. Does not satisfy requirements for entry into course where prerequisite are
specified.

0 - 59% F – Failure
Non-passing grade indicating failure to meet minimum requirements as outlined in
the course training packet. Earned as a result of some or all of the following: non-
passing examination scores, inaccurate, incomplete or late assignments, failure to
cope with abstract ideas, inadequate mastery of pertinent skills, repeated absences
from class. Does not satisfy requirements for entry into course where prerequisites
are specified.

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Pass Acceptable performance
A grade of “P” represents satisfactory achievement that would have been graded
“C” or better on the grading scale, but is given instead of a letter grade. By the
end of the eighth (8th) week of class (or equivalent) students shall choose the
graded or pass option. If they don’t choose the pass option, the class will be letter
graded. By the end of the eighth (8th) week of class or equivalent), students may
rescind an earlier request of the pass option.

No Pass No Pass
Unacceptable performance or does not satisfy requirements for entry into courses
where prerequisites are specified. This grade may be used in situations where an
instructor considers the “F” grade to be inappropriate. The NP mark is
disregarded in the computation of the grade point average.

CIPR Course In Progress Re-register

A mark used to only for designated classes. To receive credit, a student must
reregister because of equipment usage is required. This may include course in
modular or self-paced programs. This mark may also be used in skill-based
course to indicate that the student has not attained the skills required to advance
to the next level. If the course is not completed within a year, the “CIPR”
changes to an “AUD” (Audit) on the transcript unless the course was repeated and
a grade earned.

AUD Audit
Some courses may allow the students to attend a course without receiving a grade
or credit for the course. Tuition must be paid, and instructor permission must be
obtained during the first three weeks of class (or equivalent). Instructors are
expected to state on their course handouts any specific audit requirements. Does
not satisfy requirements for entry into courses where prerequisites are specified.

Repeated Courses
Courses with grades of “D,” “F,” “NP,” or “CIP,” and “CIPR,” may be repeated
for a higher grade. All grades earned will appear on the transcript. The first
earned grade of “C” or “P” or better will count in the accumulated credit total.
The first grade of “C” or better will be used for the GPA calculation.

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SPECIAL If you have a special limitation or disability, which requires support services or
NOTE: special assistance please notify your instructor.

IMPORTANT:
Grades will no longer be mailed to you automatically. You may request a copy
by calling: T.R.A.I.L. at 977-5000 and select Option 4. Or you can access your
grades on the World Wide Web at https://banweb.pcc.edu/.

Notice:
All projects must be completed in the PCC Welding Lab within your course time.

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 Training Packet Directions

• All projects must be approved by your instructor.

• Bring your training packet to class everyday.

• The Welding program is based on “hands-on training” with your instructor on an

individual basis. Communication with your instructor is essential for success in the
welding program.

• Use the project sheets to note any problems, questions, or findings that you want to
discuss with your instructor.

• Carefully study the information sheets, videos, reading assignments and work sheets.
This will assist you in understanding the principles of the GTAW process and will allow
you to advance through this training packet at a faster rate.

Observe all Safety Rules

Use Your Time Wisely

Practice, Practice, Practice

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 G.T.A.W. Introduction
GTAW (Gas Tungsten Arc Welding), TIG (Tungsten Inert Gas), also sometimes referred to as
“Heliarc.” Heliarc was a trade name of one of the first manufactures of the GTAW power
sources. The GTAW process was developed in the period of 1940-1960 and rapidly became an
indispensable welding process.

The complete name for the process is:

Gas Refers to the substance that blankets the molten puddle and the arc. This
gas is inert which means that the gas will not combine chemically with
other elements and is nonflammable.

Tungsten Refers to the nonconsumable electrode that conducts electric current to the
arc.

Arc Indicates that the welding is done by an electric arc rather than by the
combustion of a gas.

Welding Coalescence is produced by heating with an arc between a tungsten

electrode and the work. A filler material may or may not be added.

Advantages
1. GTAW will make high quality welds in almost all metals and alloys.
2. No flux is required and finished welds do not have to be cleaned.
3. The arc and weld pool are clearly visible to the welder.
4. There is no filler metal carried across the arc so there is no spatter.
5. Welding can be performed in all positions.
6. There is no slag produced that might be trapped in the weld.
7. There is a minimum distortion of the metal near the weld. The heat is
concentrated in
a small area resulting is a small heat-affected zone.
8. In the chemical composition, the weld is usually equal to the base metal. It is
usually stronger, more resistant to corrosion, and more ductile than welds made
by other processes.

Disadvantages
1. More complex and expensive equipment is required.
2. Higher operating cost (Argon gas and tungsten electrodes).
3. Higher degree of manipulative skill is required.
4. Extensive material preparation required. Welding area must be free of contaminants
such as oil, paint, rust, etc.
5. Limited area of operations (nearly ideal conditions are required compared to other
welding processes).
6. Slower deposit rates than other processes.

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 Uses of GTAW
The GTAW process is used when high quality and purity of the weld have priority over welding
speed. GTAW is used in many welding manufacturing operations, primarily on thinner materials
where metal finishing is not desired. It is very useful for maintenance and repair work, for die
castings and unusual metals. GTAW is widely used for joining thin wall tubing and for making
root passes on pipe joints.

The aircraft industry is one of the principle users of this process on such materials as aluminum,
magnesium, titanium, and stainless steel. Products produced using GTAW include: space
vehicles, rocket and jet engines, nuclear power industries, tanks, boilers and medical equipment.

INTRODUCTION TO ALUMINUM
PROPERTIES AND WELDABILITY OF ALUMINUM

Aluminum has a number of properties that make welding it different from welding steels.
These are:
Aluminum oxide surface coating (melting temperature of approximately 3,300F).
• High thermal conductivity
• High thermal expansion
• Low melting point 1100 to 1200 F depending upon alloy content.
• The absence of color change as temperature approaches melting points.

1. The rapid formation of oxides in aluminum make material preparation a critical step in the
welding procedures. After the surface is cleaned, welding should be performed within
eight hours to ensure weld quality. Surface should be cleaned prior to welding and then
welded immediately.

2. Aluminum conducts heat three to five times faster than steel. This means that higher
currents are required during welding even though the melting point of aluminum is less than
half that of steel. Because of the high thermal conductivity, preheat is often used on thicker
sections. The high heat conductivity of aluminum is helpful in that heat leaves the weld
area quickly, causing the weld pool to solidify rapidly. This helps hold the weld metal in
position and makes all position welding easier.

3. The thermal expansion of aluminum is twice that of steel. In addition, aluminum welds
decrease about 6% in volume when solidifying. This may cause distortion and cracking.

4. Aluminum is light weight, very ductile, malleable, non-magnetic, highly reflective, and may
be heat treated, work hardened, and alloyed with other elements to improve its properties for
a wide variety of applications.

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 CLASSIFICATION OF ALUMINUM
Aluminum alloys are broadly classified as castings or wrought material. Our focus will be on the
wrought alloys. This group includes alloys that are designed for mill products whose final
physical forms are obtained by working the metal mechanically, rolling, forging, extruding, and
drawing. These products include: sheet, plate, wire, rod, bar, tube, pipe, forgings, angles,
structural channels, and rolled and extruded shapes.

The Aluminum association has designed a four digit index system for designating wrought
aluminum and its alloys.

The first digit identifies the alloy group:

Aluminum Alloy Designation

Aluminum - 99.0% 1xxx
Copper 2xxx
Manganese 3xxx
Silicon 4xxx
Magnesium 5xxx
Magnesium and Silicon 6xxx
Zinc 7xxx
Other elements 8xxx
Unused series 9xxx

Second digit indicates modification or impurities, last two digits indicate minimum aluminum
percentage, i.e. 1075 is 75% pure aluminum.

Example:

6061 Aluminum

6 = Magnesium and Silicon is the major alloy group

0 = no modifications or significant impurities
61 = percent aluminum

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 MAJOR ALUMINUM ALLOYS AND THEIR APPLICATIONS
Alloy Description of Major Typical Typical Additions
Series Alloying Alloys
Element
1xxx 99.00% Minimum 1350 Electrical conductor
Aluminum 1060 Chemical equipment, tank cars
1100 Sheet metal work, cooking utensils,
decorative
2XXX Copper (Al-Cu)
2011 Screw Machine parts
2219 Structural, high temperature
(Al-Cu-g)
2014 Aircraft structures and engines, truck
frames and wheels
2024
2618
3XXX Manganese 3003 Sheet metal work, chemical
3004 Equipment, storage tanks
4XXX Silicon 4032 Pistons
4043 Welding electrode
4343 Brazing Alloy
5XXX Magnesium 5005 Decorative, architectural
5050 Anodized automotive-trim
5052 Sheet metal work, appliances
5657
(>3%Mg)
5083 Marine, welded structures
5086 Storage tanks, pressure
5454 Vessels, armor plate
5456 Cryogenics
6XXX Magnesium and Silicon 6061 Marine, truck frames
6063 Bodies, structures, architectural,
furniture
7XXX Zinc (Al-Zn-
Mg)
7004 Structural, cryogenics, missiles
7005 (Al-An-Mg-Cu)
7001 High strength structural
7075 Aircraft
7178

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 ALUMINUM ALLOYS
A temper designation system is used to indicate the condition of a product. It is based on the
sequence of basic treatments used to produce the desired mechanical properties. This
designation follows the alloy designation. Subsequent divisions of the basic letter tempers are
indicated by one or more digits following the letter. These digits designate a specific sequence
of basic treatments.

BASIC TEMPER DESIGNATIONS FOR ALUMINUM ALLOYS

F As-Fabricated
O Annealed
H1 Strain hardened only
H2 Strain hardened and partially annealed
H3 Strain hardened and thermally stabilized
W Solution heat-treated
T1 Cooled from an elevated temperature shaping process and naturally aged
T2 Cooled from an elevated temperature shaping process, cold worked and naturally aged
T3 *Solution heat-treated, cold worked, and naturally aged
T4 Solution heat-treated and naturally aged
T5 Cooled from an elevated temperature shaping process and then artificially aged
T6 Solution heat-treated and then artificially aged
T7 Solution heat-treated and stabilized
T8 Solution heat-treated, cold worked, and then artificially aged
T9 Solution heat-treated, artificially aged, and then cold worked
T10 Cooled from an elevated temperature shaping process, cold worked, and then artificially
aged

*Achieved by heating to and holding at a suitable temperature long enough to allow constituents
to enter into solid solution and then cooling rapidly to hold the constituents in solution.

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Nonheat-Treatable Alloys

The initial strengths of the nonheat-treatable alloys depend primarily upon the hardening effect
of alloying elements such as silicon, iron, manganese, and magnesium. These elements increase
the strength of aluminum by formation of dispersed phases in the metal matrix or by solid
solution. The nonheat-treatable alloys are mainly found in the 1XXX, 3XXX, 4XXX and 5XXX
series depending upon their major elements. Iron and silicon are the major impurities in
commercially pure aluminum, but they do contribute to its strength. Magnesium is the most
effective solution-strengthening addition. Aluminum magnesium alloys of the 5XXX series
have relatively high strength in the annealed condition. All of the nonheat-treatable alloys are
work hardenable.

The nonheat-treatable alloys may be annealed by heating to an elevated temperature to remove

the efforts of cold working and improve ductility. The proper annealing schedule to use will
depend upon the alloy and its temper. When welding the nonheat-treatable alloys, the heat
affected zone may lose the strengthening effects of cold working. Thus, the strength in this zone
may decrease to near that of annealed metal.

Heat-Treatable Alloys

The heat-treatable alloys are found in the 4XXX, 6XXX and 7XXX series. The strength of any
of these alloys depend only upon the alloy composition, in the annealed condition as do the
nonheat-treatable alloys. However, copper, magnesium, zinc, and silicon, either singularly or in
various combinations, show a marked increase in solid solubility in aluminum with increasing
temperature. Therefore, these alloys can be strengthened by appropriate thermal treatments.

Heat-treatable aluminum alloys develop their improved strength by solution heat treating
followed by either natural or artificial aging. Cold working before or after aging may provide
additional strength. Heat-treated alloys may be annealed to provide maximum ductility with a
sacrifice in strength properties. Annealing is achieved by heating the component at an elevated
temperature for a specified time, and then cooling it at a controlled rate.

During welding, the heat-affected zone will be exposed to sufficiently high temperatures to
overage heat-treated metal. As a result this zone will be softened to some extent.

Reprinted from American Welding Society Welding Handbook, Seventh Edition, Volume 4,
Metals and Their Weldability.

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 RECOMMENDED PROCEDURES FOR GTAW OF ALUMINUM
Plate Welding Alternatin Electrode Argon Filler Rod Number
Thickness Position g Current (b) Gas Flow Diameter of
(in) (a) (amp) Diameter (c) (in) Passes
(in) (cfh)
1/16 F 70-100 1/16 20 3/32 1
H, V 70-100 1/16 20 3/32 1
O 60-+90 1/16 25 3/32 1
1/8 F 125-160 3/32 20 1/8 1
H, V 115-150 3/32 20 1/8 1
O 115-150 3/32 25 1/8 1
¼ F 225-275 5/32 30 3/16 2
H, V 200-240 5/32 30 3/16 2
O 210-260 5/32 35 3/16 2
3/8 F 325-400 ¼ 35 1/4 2
H, V 250-320 3/16 35 1/4 2
O 275-350 3/16 40 1/4 2
½ F 375-450 1/4 35 1/4 3
H, V 250-320 3/16 35 1/4 3
O 275-340 3/16 40 1/4 4
1 F 500-600 5/16-3/18 35-40 1/4-3/8 8-10

• F = Flat; H = Horizontal; V = Vertical; O = Overhead.

• Diameters are for standard pure or zirconium tungsten electrodes. Thoriated

tungsten electrodes not generally used for AC TIG.

• Helium is not generally used in AC TIG welding aluminum. When Helium is used flow
rates are about twice those used for argon.

Many factors affect a welding procedure other than those listed above. These available
guidelines are helpful to give the welder a starting point for machine adjustments.

Some operating variables that affect a weld procedure are:

1. Are length
2. Rate of travel
3. Amount of filler added
4. Joint type
5. Material dimensions
6. Material preparation

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 GTAW Power Sources
The welding power source used for GTAW is a constant current type of output. GTAW power
sources may also be used for SMAW (Shielded Metal Arc Welding “stick”). There are a variety
of types and models of GTAW power sources. Power source controls vary greatly from one
manufacturer to another and from one model of machine to another. New technology is rapidly
changing welding power sources, therefore it is necessary to study in greater detail the many
adjustments available on the “state of the art” power sources in use today. We have utilized the
owners manual information to review the controls on the different power sources. For the
purpose of this course, the focus will be on the power source controls that will be used during
your Aluminum.

One of the many advances in welding power sources is the use of graphic symbols to identify
controls. This provides communication on an international level. Please see the chart of graphic
symbols following the power source information.

An important outcome of your training is to develop knowledge and skills in the operation of a
variety of GTAW power sources. This course will introduce the basic functions of the following
GTAW power sources;

• Lincoln Idealarc 300

• Lincoln Square Wave 255
• Lincoln Square Wave 275
• Lincoln Square Wave 355
• Miller Syncrowave 350LX
• Miller Syncrowave 250

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 Lincoln Idealarc 300
Standard Power Source Controls
Current Selector Switch
This allows you to select the welding current desired. The type of material to be welded
determines the current choice. Alternating Current High Frequency (ACHF) is the current choice
for aluminum.

Coarse Current Range Selector

This adjustment allows you to select a wide current range usually labeled simply Low, Medium,
and High with the minimum and maximum amperage available within each range listed below
the range setting. Most of the newer machines have a single wide current range instead of low,
medium and high, this allows adjustment of the full range of the current available

Fine Current Adjustment

This adjustment allows you to select what percentage of the coarse range you wish to use.
Usually a dial labeled 1 through 10. For example, if you have selected low range and your fine
adjustment is set at 5, your available current will be 50% of the maximum current listed for low
range.

Standard/Remote Contactor Control Switch

When a remote contactor, such as a foot peddle for GTAW is being used, this switch must be in
the "remote" position. The switch should be in the "standard" position when using the power
source for SMAW.

Remote Amperage Control Receptacle

This receptacle is provided for connecting a remote hand or remote foot control. This allows the
operator to have amperage control while welding. When the foot control is completely depressed
your welding current will be the maximum available as determined by coarse and fine current
settings.

Post Flow
This adjustment is an after timer for the flow of gas, sometimes labeled "post purge" or "after
flow." This adjustment controls the length of time that the gas flows after the arc is broken. The
flow of gas after the arc is broken protects the tungsten from atmospheric contamination as it
cools, and protects the molten weld pool as it solidifies.

High Frequency Switch (also known as “Spark”)

The high frequency current serves two purposes in GTAW. It provides a non-touch start in arc
initiation and stabilizes the arc during AC welding applications. The switch has three positions,

Continuous: Sometimes labeled "ON." In this position the high frequency is present all
of the time during welding. When welding with AC it is necessary to have continuous
high frequency to stabilize the alternating current.

Off: Eliminates the presence of the high frequency. This setting is used when the power
source is used for SMAW (stick).

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 Start: In this position the high frequency is present only to initiate the arc, once the arc is
established it shuts off. This position is the choice when welding with DCSP.
High Frequency Adjustment
This control is a dial that allows you to increase or decrease the strength of the high
frequency current. Sometimes labeled High Frequency Intensity.

Power Switch
This control turns the welding machine on and off.

Tig and Stick Switch

This control allows the welder to change back and forth between GTAW and SMAW.

Lincoln Idealarc 300

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 Lincoln, Square Wave 255

Controls and Settings for the Square Wave 255

1. Weld Mode Keys 2. Current Control Keys

3. High Frequency Keys 4. AC Wave Balance
Keys
5. TIG Pulser Keys 6. After-flow Keys
7. Display

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 New Advanced Power Source Controls
Control Panel Keys for the Lincoln Square Wave 255
The keys are grouped into six areas, described below. Some areas are active in both TIG and
Stick, while others are active in TIG only. The red indicator lights identify which functions are
active.

1. WELD MODE KEYS: These keys select the Weld mode desired, as the graphic symbols
indicate the TIG 2-Step mode is selected when using a Foot Amptrol (foot operated remote
current control), the TIG 4-Step is selected when using a Hand Amptrol ( hand operated
remote current control, usually mounted on the torch). The third mode is selected when using
the power source for Stick welding.

2. CURRENT CONTROL: This area contains the Local/Remote keys as well as the Amps
Up/Amps Down keys. The up/down keys are used to adjust amperage from 5 to 315 amps.
The “Local” current control allows the current to be adjusted only with the Amps up/Amps
down keys. The “Remote” current control is automatically activated when using the TIG 2-
Step and TIG 4-Step modes.

3. HIGH FREQUENCY: These keys are active in the TIG mode only. Select “Start Only”
when using Direct Current straight polarity. Select “Continuous” when welding with
Alternating Current. “Off” will automatically be selected when welding in the Stick mode.

4. AC WAVE BALANCE: These keys are active in the AC TIG mode only. They are used to
set the amount of cleaning and/or penetration. Auto Balance automatically sets the AC Wave
balance according to the welding current.

5. TIG PULSER: These keys are active in the TIG mode only. The On/Off keys turn the pulse
option on and off. The Pulses Per Second keys adjust the pulsing frequency up and down,
from 0.5 to 10 pulses per second. The background current (the welding current at the low
point of the pulse cycle) is automatically adjusted from 40% to 60% of the peak current (the
welding current selected). The ratio between the time spent at peak current verses, the time
spent at the background current is fixed at 50%.

6. AFTERFLOW: These keys are active in the TIG mode only. These keys adjust the length of
time the gas flows after the arc is extinguished.

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 Lincoln, Square Wave TIG 275
Controls for the Lincoln Square
Wave TIG

Controls for the Lincoln Square Wave TIG 275

1. Current Control Knob 2. AC Wave Balance Knob

3. Post Flow Knob 4. Down Slope Time Knob
5. Mode Switch 6. Trimmer Potentiometer
7. Digital Ammeter 8. Digital Voltmeter
9. Thermal Protection Light 10. Power Switch
11. Polarity Switch 12. Electrode Connection
13. Work Connection 14. Remote Control Amphenol
15. Water Solenoid

Note:
The Lincoln Square Wave 275 does not have a separate high frequency switch. The high
frequency is built into the polarity switch.

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 Lincoln, Square Wave TIG 355

Miller, Syncrowave 350LX

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 Controls and Settings for the Miller Syncrowave 350LX

1. Process Control 2. Current Control

3. Output Control 4. Start Mode Button
5. Voltmeter 6. Ammeter
7. Amperage Adjustment Control 8. Output Selector Switch
9. Power Switch (on/off) 10. Post Flow Time Control
11. Pre Flow Time Control 12. Balance/Dig Control
13. Pulser On/Off Switch 14. Back Ground Amperage
Control
15. Pulses Frequency Control 16. Peak Time Control
17. Sequence Controls (Optional) 18. High Frequency Control

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Symbols and definitions for the Miller Syncrowave 350LX and Lincoln Squarewave Tig 355

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 Miller, Syncrowave 250

Controls and Setting for the Miller Syncrowave 250

1. Ammeter 2. Voltmeter
3. High Frequency Switch 4. Output (contactor) Switch
5. Amperage Control Switch 6. Spot Time Switch and Control
7. Pre-flow Time Control 8. AC Balance Control
9. Crater Time Switch and Control 10. Amperage Adjustment Control
11. Arc Force (dig) Switch and 12. Post-flow Time and Control
Control
13. High Temperature Shutdown 14. Power Switch and Pilot Light
Light
15. Output Selector Switch 16. High Frequency Control

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 Symbols and Definitions for the Miller Syncrowave 250

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 TORCH ASSEMBLY

The Gas Tungsten Arc Welding torch functions as an: electrode holder; a conduit for the
shielding gas and coolant if used; and for a conductor of the welding current. Torches are
available in a variety of sizes and shapes. Torches are rated by the maximum amperage they can
carry. For example, air cooled torches are normally rated at about 150 amperes. This is the
maximum welding current that can be safely used. Some water-cooled torches are rated up to
500 amperes.

The typical GTAW torch has several parts that include:

1. The cap seals the back of the torch and tightens to hold tungsten in place. Caps
are available in a variety of sizes. The one shown is for a seven inch long
tungsten.
2. "O" ring - fits on the cap to insure an air tight seal on the back of the torch.
3. The tungsten is placed inside the torch. Tungstens are available in a wide variety
of diameters and lengths.
4. Electrode collet
The collet holds the tungsten in place. The collet size must be the same as the
tungsten diameter. For example, if you are using a 1/16” diameter tungsten you
will need a 1/16” collet.
5. Collet Body
The collet body holds the collet in position and also disperses the shielding-gas
into the gas cup. Some torches have universal collet holders. The torches in our
shop do not. The collet and collet body must be the same size as your tungsten
diameter.
6. Torch body
Torch bodies are available in a variety of sizes and shapes. They are threaded in
the front and back for assembly.
7. Gas nozzle
More commonly known as "gas cup," it directs the shielding gas over the weld
pool. Cups are usually made of a high heat ceramic and are available in many
sizes. Cup size will vary with joint type for accessibility and tungsten diameter.
Your cup should be 4 to 6 times larger than tungsten diameter. Cup sizes are
measured in 1/16” of an inch. For example, a number 4 cup would measure 4/16”
inch (1/4”) in diameter and would be suitable for up to 1/16” diameter tungsten.

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 Tungsten Electrodes
Tungsten and tungsten alloys are the choice for electrode material because tungsten has the
highest melting point of all metals (6,170° F) (3,410° C). Tungsten also offers low electrical
resistance, good heat conductivity, and the ability to easily emit electrons. Four classes of
tungsten electrodes have been standardized by the American Welding Society (AWS).
Shown below are AWS classifications and color codes for the end of the electrodes.

AWS Classification* Type End Color

E.W.P. Pure Tungsten green
EWTH-1 1% Thorium added yellow
EWTH-2 2% Thorium added red
EWZr 50% Zirconium added brown
Available diameters 0.020 to 0.250 inch (0.5 to 6.4 mm).
Available lengths 3 to 24 inch (76 to 610 mm).

*AWS Classification System for Tungsten:

EWTH-2 - E - electrode EWP - E - electrode,
W - atomic symbol for W – tungsten (Wolfram)
Tungsten (Wolfram) P – pure
Th2- alloy containing 2%
Thorium

Pure tungsten is generally used for AC welding. The zirconium type is also excellent for AC.
Thoriated tungsten electrodes are available for direct current straight polarity welding. The
addition of thorium increases the current carrying capacity of the tungsten.

Tungsten selection
The material to be welded and the type of current used are the determining factors in the
selection of type of tungsten. When welding aluminum use ACHF with a pure tungsten
(EWP). The selection of tungsten diameter will depend on the current range being used
and the thickness of the metal to be welded. The following chart recommends current
ranges for tungsten diameters.

Typical current ranges for tungsten electrodes, ACHF, with Argon shielding gas

Current Range (Amp.) Electrode Diameter (in.)

5 – 20 0.020
15 – 80 0.040
70 – 150 1/16
150 – 250 3/32
250 – 400 1/8
350 – 500 5/32
500 – 750 3/16
750 – 1000 ¼

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 Recommended. ACHF Current Ranges for EWP

Electrode Current Range

Diameter (Amperage)
0.10” 8-15

0.20” 10-20

0.40” 15-50

1/16” 40-140

3/32” 90-160

1/8” 140-210

5/32” 180-275

3/16” 240-340

¼” 280-490

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 Tungsten Preparation
A "balled" or rounded taper is used for welding aluminum. This is done because it allows for a
wider cleaning action during welding.

During the reverse polarity half cycle of the A.C., the ionization of the gas bombards the weld
surface. Direction of current flow during the reverse polarity half cycle is from the work (-) to
the electrode (+). This direction of flow lifts the oxides from the weld surface, resulting in the
"cleaning action."

The ball may be formed in two ways

A. Increasing the amperage range to the maximum recommended for the tungsten diameter
and
initiating the arc will cause the tungsten to consume itself forming the rounded tip. Too
much amperage will cause the ball to enlarge or melt off. Vibration of the ball and
enlarging of the ball are indications that the current range is too high for the electrode
diameter, or the electrode is too small for the current required.

The ball on the tip of the tungsten should not exceed 1-1/2 times the tungsten
diameter. The smaller the ball the better because this helps focus the arc.

B. The ball my also be formed by adjusting the polarity switch to DC + DCRP (Direct
Current Reverse Polarity) and initiating an arc. In critical applications this is sometimes
done on a clean copper bar to avoid contamination of the tungsten.

The condition of the tungsten is an important factor in successful weld results. If the tip
becomes contaminated during welding, the contaminated portion should be broken off
and the tip redressed.

ALWAYS WEAR EYE PROTECTION WHEN GRINDING A TUNGSTEN!!! Tungsten

electrodes are very brittle and easily shattered.
The condition of the tungsten tip is a very important factor in successful weld results. If the
tip becomes contaminated during welding, it must be re-balled.

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 Shielding Gases
The type of shielding gas used in GTAW is inert. Inert means that the gas does not form
compounds with other elements and is nonflammable. Argon and helium are two inert shielding
gases used in GTAW.

Argon is most commonly used. It is readily available, heavier than helium and slightly heavier
than air. This provides a more efficient arc shielding at lower flow rates. Argon is also better for
arc starting and operates at lower arc voltage.

Helium provides higher arc voltage resulting in deeper penetration than argon. It is also possible
to weld at higher speeds with helium. Helium is lighter than Argon or air and tends to float away
from the weld zone so higher flow rates are required. In some cases argon and helium are mixed
together for a particular welding application.

Shielding gas may be supplied from cylinders or a manifold system. A combination regulator
and flow meter is usually used. The regulator reduces the high pressure of the cylinder to a
usable working pressure. The flow meter provides uniform flow of shielding. It is calibrated to
show flow in cubic feet per hour (c.f.h.).

Gas flow should be adjusted by turning the adjusting knob. You will need to reference
the flow meter’s plastic tube to determine whether reading the top, middle, or bottom of
the ball when setting the flow. These directions are most commonly printed at the
bottom of this tube. Also note that because gases have different densities, the plastic tube
will generally have 2 to 3 different gas options to select from. Be sure to read the gas
scale for the gas you have selected.
Flow meter Cylinder
adjusting on/off
knob valve

Cylinder Safety valve

Pressure for the
Gage cylinder

15 to 20 cubic feet per hour (c.f.h.) of argon is usually a good working range. Some factors that
may affect the flow rate are listed below:
1. Type of shielding gas 4. Size of cup
2. Type and design of weld joint 5. Size of puddle
3. Cup to work distance 6. Position of welding
7. Air drafts in the welding area

In some cases, argon and helium are mixed together for a particular welding application.

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 FILLER COMPOSITION
Selection of a compatible filler rod is an important step in successful welds. The filler metal
composition must be compatible with the composition of the base material or cracking will
result. Filler rods are classified in the same way as wrought aluminum alloys.

A relatively small number of filler alloys can be used to weld a wide range of aluminum alloys.
Certain filler alloys, 5356 or 5183 for example, can be used for practically all aluminum
welding.

The chart below offers electrode selection based on joint requirements. Those listed under the
"strength" group produced stronger and harder weld composite. The group "elongation" produce
softer, more ductile welds.

Recommended filler rod for various aluminum alloys.

Recommended Filler Metal

Base Metal For Maximum As-Welded For Maximum
Strength Elongation
EC 1100 EC, 1260
1100 1100,4043 1100, 4043
2219 2319 (2)
3003 5183, 5356 1100, 4043
3004 5554, 5356 5183, 4043
5005 5183, 4043, 5356 5183, 4043
5050 5356 5183, 4043
5052 5356, 5183 5183, 4043, 5356
5083 5183, 5356 5183, 5356
5086 5183, 5356 5183, 5356
5154 5356, 5183 5183, 5356, 5654
5357 5554, 5356 5356
5454 5356, 5554 5554, 5356
5456 5556 5183, 5356
6061 4043, 5183 53563
6063 4043, 5183 53563
7005 5039 5183, 5356
7039 5039 5183, 5356

Notes:
1. Recommendations are for plate of "0" temper.
2. Ductility of weldments of these base metals is not appreciably affected by filler metal.
Elongation of these base metals is generally lower than that of other alloys listed.
3.For welded joints in 6061 and 6063 requiring maximum electrical conductivity, use 4043 filler
metal. However, if both strength and conductivity are required, use 5356 filler metal and
increase the weld reinforcement to compensate for the lower conductivity of 5356.

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 Math

on

Metal
The Welding Fabrication Industry needs qualified welder fabricators who
can deal with a variety of situations on the job. This portion of the training
packet explores math as it relates to industry requirements.

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 Setting the Dials to Obtain the Correct Amperage Settings
Amperage is the measure of current flow. The more amps you have, the more current you will
have. In order to obtain the best weld possible you must accurately set the amperage to the
specified level. This can be challenging because the amperage settings on every machine are
different. On most machines there is an amperage range setting and a fine adjustment. The
newer machines are less confusing to use, but most shops, unless they specialize, will have older
machines.

In this packet you will be welding aluminum using Alternating Current (AC). When choosing
your range make sure that you are on the alternating current settings.

We will discuss the settings on three different machines:

• Miller Syncrowave 250
• Sureweld
• Lincoln Ideal Arc Welder TIG 300/300

Miller Syncrowave
The easiest machine to set is the Miller Syncrowave. It is the newest machine and has just one
dial to set.

Notice that the amperage adjustment on this machine goes from 0-310 amps.

The dial is set in 50 amp increments from 50 to 300 amps. i.e. 50, 100, 150….until you reach
300. The very low setting and the highest setting have are different and will be discussed later.

There are no graduations between the numbers so you cannot set this dial to exact amperage.
You can only come close.
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Since you know that there is a 50 amp difference between any two numbers on the dial between
50 and 300, you can estimate that half way between any two of those numbers is 25 more amps
than the lesser of the two numbers.

Halfway between 50 and 100 would be 50 +25 or 75 amps. (like the dial setting below on the
left) Halfway between 200 and 250 would be 200 + 25 or 225 amps. (like the dial setting below
on the right)

What if I need a setting of 110 amps?

Turn the machine to the 100 amp setting. You know that a additional 10 amps is 1/5 of the way
to 150 amps, so set your dial as pictured below on the left. Since you don’t know exactly where
1/5 of the distance from 100 to 150 is located, you just estimate.

Look at the dial to the right above and the dial pictured below. Determine what the approximate
amperage setting are. Explain your thinking process.

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Reading Very Low and Very High Settings

Look at the lowest settings and the highest settings on the amperage adjustment below. The
lowest numbers are 0, 10 and 50. The highest settings are 300 and 310. If your amperage setting
is below 50 or above 300 you will divide the space up differently. Between 0 and 10 amps there
are only 10 amps. Half way between them is 5 amps; a quarter of the way between them is 2.5
amps etc.

Between 300 and 310 there are also only ten amps so the same logic applies. Half way between
them is 305 amps, etc.

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Sureweld

Next look at this picture of the Sureweld

The Sureweld has three AC amp range settings. They are:

• 5-48
• 20-230
• 190-435

Choose the lowest range which includes your intended amperage setting. If you needed a
setting of 200 amps you would choose the 20-230 amp range because it is the lowest range that
contains that setting

The Sureweld also has a fine adjustment dial that is labeled from 0-100. You can think of this
dial as indicating a percent of the total amps in a given range. Remember the range is the
difference between the greatest number and least number of amps given. Each graduation on the
dial stands for 2% of the total amount of current available in that range. (notice that if you are
counting the graduations on the dial you would count by two’s in order to get around the dial and
reach 100).

If your lever is set in the middle range (20-230 amps) the 0 on the dial would indicate 20
amps and the 100 would represent 230m amps or 100% of the available amperage on the
range.

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 Because this is a percentage problem, you can use the box method to solve it.

Another way to look at this is that we know that each graduation is worth 2% of the range. So we
can use the box to determine how much each graduation is worth in a given range.

Amps %
(210 x 2) ÷ 100 = 4.2 amps ? 2
210 ÷ 100

For the middle range each graduation on the dial is worth 4.2 amps. Remember we start
counting at 20 amps (the low end of the range) and then add 4.2 amps for each graduation) We
could count 28 graduations in order to get to 140 or we can do it an easier way.

• We know that we want to set the dial for 140 amps.

• We know that each graduation in the middle range is worth 4.2 Amps
• We know that the dial starts at 20 amps

Take the dial setting you want, 140amps, and subtract 20 amps 140-20 = 120

Divide 120 by 4.2 to determine where you would set the dial.

120 ÷ 4.2 = 28.57

To get 140 amps you would set the dial between 28 and 29

What if we wanted a dial setting of 75 amps?

Take the dial setting you wish to get (75amps), and subtract 20 amps 75-20 = 55 amps

Divide 55 by 4.2 to determine where you would set the dial.

55 ÷ 4.2 = 13.09

To get 75 amps you would set the dial on 13.

If you are using the upper range of 190 –435 amps, what would each graduation on the dial be
worth?

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 Lincoln Arc Welder

The third machine that you might use on your welding projects for this packet is the Lincoln Arc
Welder- Ideal Arc TIG 300/300. Look at the first picture below. It shows the current range
selector lever.

There are five possible AC ranges that you can choose from. They are:
• Minimum 2-25 amps
• Low 10-85 amps
• Medium 15-140 amps
• High 25-225 amps
• Maximum 60-375 amps

Set the current range selector to the lowest range that includes your intended amperage
setting.

Which range would you use if you wanted 30 amps?

The Lincoln arc welder also has a fine current adjust setting as pictured below.

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Notice the dial on the fine adjustment current control is labeled one to ten. There are no
graduations between the numbers. You will only be able to get an approximate setting using this
dial. It is impossible to be exact. In any case the number one represents the bottom number of
your range and the number 10 represents the top number of your range.

To determine what each number in between one and ten means, you count the number of
segments the dial is divided into. The answer is nine segments. There are 10 numbers but only
nine spaces. You then determine the difference in the high and low of the range you are working
in. Lets say we want to know what each number means in the low range (10-85 amps). When
you see the word “difference’ it means subtract.

85-10 = 75 amps. The difference between the high and the low in the low range is 75 amps.

You then take the difference in the range, 75 amps, and divide it by the number of segments on
your dial. (9)

75÷ 9 = 8.33 amps. 8.33 is the number of amps between each dial setting in the low range.

Each number on the dial represents an additional 8.33 amps when you are in the low
range. So the number 1 is 10 amps (the lowest number of amps on the low range). The number
two represents 18.33 amps. (10 amps + 8.33 amps) The number three represents 26.66 amps.
(18.33 amps + 8.33 amps) and so on.

To determine where a specific amperage is on the low range follow these steps:

Let’s say that we want to locate 60 amps on the low range setting
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 1. Determine what each segment on the dial is worth in the particular range. In this
case 8.33 amps

2. Subtract the low number of the range (10 amps) from the total amps that you want
in for your dial setting. (60)

60 amps 10 amps = 50 amps

3. Divide 50 amps by the amount each segment is worth 50 ÷ 8.33 = 6.002

4. Set the dial on six in order to get 60 amps.

What if I want to set my dial for a number of amps that is not represented by a number on the
fine adjustment dial? You would then find the closest number and estimate where you would set
the dial. For example if I needed 25 amps on the lowest range setting? I would set the dial
slightly before the 26.66 amp setting which would be the number 3.

Remember every time you change the range you change how many amps each number on
the fine adjustment dial is worth.

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Let’s set the machine for 125 amps.

Step #1 Set the range selector to the number of AC amps that are required. In this case we
would choose the medium range (15-140 amps) because it is the lowest usable range.

Step #2 Determine what the numbers mean on the fine adjustment current control dial. To do
this: Subtract 15 from 140, the low of the range from the high of the range.

140-15= 125 amps

Divide 125 amps by the nine segments on the dial (125 ÷ 9) and you determine that each number
is worth 13.88 amps.

Step #3 Set the dial by taking the intended setting (125 amps) and subtracting 15 amps, the
bottom of the range. 125- 15 = 110 amps. Divide this number (110) by the amount each
segment is worth.

110 ÷ 13.88 = 7.92

Step #4 Set the dial just before the number eight. The number 8 represents 125 amps when set
on the medium range.

Now you practice. Using the high scale (25-225 amps) how would you set the fine adjustment
in order to get 145 amps? Please show your work.

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 Chart Reading for Welders
Look at the chart in your packet entitled: ‘Recommended Procedure for GTAW of Aluminum’

Answer the following questions about this chart.

1. What is the approximate helium flow rate for a plate that is 3/8 inch thick when you are
using 250-320 amps?

2. What is the filler rod diameter for ¼ inch plate thickness?

3. In what position(s) can you weld a plate that is 1/16inch thick?

4. In what position(s) can you weld a plate that is 1 inch thick?

5. What is the recommended argon gas flow for a ½ inch plate thickness?

6. What plate thickness and electrode diameter are recommended with an alternating current
setting of 425 amps?

7. What is the recommended number of passes on a 3/8 inch plate when the argon gas flow
is 35 c.f.h.?

8. Define the following units:

a. c. f. h.

b. amp

c. diameter

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 Science

on

Aluminum
The Welding Fabrication Industry needs qualified welder fabricators who
can deal with a variety of situations on the job. This portion of the training
packet explores science as it relates to industry requirements.

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Contents of this Packet include
A. Weld Cleanliness and Porosity
B. What is the Arc Plasma in GTAW?
C. Causes of Porosity in Aluminum Welds
D. AC Power to Weld Aluminum
E. DC-EP Current to Weld Aluminum
F. DC-EN Current to Weld Aluminum
G. Pure Tungsten vs Zirconiated Electrodes

Weld Cleanliness and Porosity

Aluminum and aluminum alloys are extremely susceptible to porosity resulting from the
formation hydrogen gas trapped in the molten weld pool. Unlike other metals, liquid aluminum
(and liquid copper) is capable of dissolving large volumes of hydrogen into the molten weld
pool. The problem occurs during solidification of the weld. The solubility of hydrogen in
solidified aluminum drops precipitously to zero. Thus, all of the hydrogen which was dissolved
in the molten weld metal, must now form gas bubbles and float out of the weld pool.
Unfortunately, the weld cooling rates are so fast that most of the bubbles are trapped in the
solidifying weld, leaving gas porosity. Small, fast-cooling welds produce many small pores
while large slower-cooling welds produce fewer but larger pores. In any case, eliminating
porosity from aluminum welds can only be achieved by good workmanship and clean welding
practice.

Unlike steel, it takes very little hydrogen to cause porosity in aluminum. Of course, if there were
no source of hydrogen in GTAW of aluminum, there would be no porosity. As a result, it may
seem like the plate, consumables and welding practice are “clean”, but, a great deal of porosity
can still occur.

Compared to SMAW, FCAW and GMAW, weld metal deposited by GTAW can be free of
porosity and contamination of any kind. GTAW is an extremely clean and hydrogen-free
process. The tungsten electrode and the molten metal pool are protected by the argon shielding
gas used in welding. If the welder uses an extra long arc (higher voltage) on a humid day,
moisture from the air can be entrained into the arc particularly if the gas flow through the gas
lens is turbulent. Once moisture reaches the high temperature arc, the water molecule
immediately dissociates into hydrogen (H) and oxygen (O) as shown below:

H2O => 2H + O
Because of the high arc temperature, the hydrogen and oxygen atoms are not only immediately
dissociated into monatomic H and O, but also ionized. That is, the hydrogen and oxygen atoms
exist as single atoms with their outer valence electron lost to the arc plasma atmosphere (plasmas
are discussed in the next section). Ionized H and O are in an activated state. H diffuses into the
molten pool, while O forms the chemical stable aluminum oxide, Al2O3. The aluminum oxide
remains at the top of the weld pool. Since aluminum can never form a stable aluminum hydride
compound, the H in the arc atmosphere simply dissolves in the molten aluminum in a liquid
solution. Just like salt dissolves in water, the hydrogen gas is dissolved in molten aluminum.

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What is the Arc Plasma in GTAW?
In order to have a steady sustained arc during GTAW, electricity must be transferred through an
electrical conducting “plasma” between the tungsten electrode and the aluminum work-piece.
How can this be accomplished if only argon gas is a non-conducting insulator. Argon and
helium are inert gaseous elements, which have a full outer shells of electrons. Because argon
and helium are considered “inert”, they do not undergo any chemical reaction. Argon and
helium will not conduct electricity at room temperature. How then is electricity is conducted
across the arc?

Fortunately, at elevated temperatures above about 5,000º C, the electrode generates copious
electrons by thermionic emission. These energetic electrons collide with the shielding gas
(argon or helium) atoms as well as the aluminum atoms in the work-piece causing the stripping
away of their outer electrons. Even though argon and helium are normally inert, high energy
electrons from the thermionic emitter provides enough energy to knock out electrons from the
outer electron shell of both argon and helium atoms. These gas atoms are now in an “ionized”
state. These electrons are now free to contribute to current flow during GTAW. The ease with
which a gas can be ionized is called the ionization potential or voltage for welding. For
example, argon ionizes more readily than helium, so argon has a lower ionization voltage
(potential) than helium. At the same time that free electrons are being produced by collisions
with thermionic electrons, positive argon ions are also produced. When argon loses an electron,
the argon atom becomes a positively charged ion. Since the electrons are small and mobile
(compared to the heavy ions), electrons support most of the current conduction. When GTAW
with DC-EN, the flow of electrons is from the tungsten cathode to the anode aluminum work-
piece. Conversely, the flow of positively charge ions is from the anode to the cathode. For
steady arc characteristics, the establishment of a neutral plasma occurs when the net positive ions
and negative electrons are equal. Thus the plasma is the state of high temperature ionized gas in
the arc containing a balance of positive and negative charges.

Causes of Porosity in Aluminum Welds

Porosity in aluminum and aluminum alloy weld metal is always caused by hydrogen gas
contamination, despite attempts by welders to maintain good workmanship. The common
sources of porosity are:

1. Long arc length

2. High heat input
3. Inadequate inert gas shielding
4. High humidity
5. Porous oxide layer in aluminum filler metal and plate
6. Oil, paint, and other hydrocarbons in area to be welded
7. High dew point temperature of the inert gas shielding.
Long arc length provides added opportunity for moisture or humidity in the atmosphere to
contaminate the gas stream. As mentioned in the previous section, the water moisture forms
hydrogen gas in the arc.

High heat input also provides added opportunity for hydrogen atoms to dissolve in the molten
aluminum pool. Because the size or surface area of the weld pool increases with increasing heat
input, more hydrogen atoms can come into contact with the top of the molten weld pool.

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Inadequate shielding gas can occur because the argon gas line is crimped or there is a hole or
leak in the gas line. Very little contamination can cause porosity in aluminum welds. If the
torch does not have a gas lens, the gas flow may not be laminar. Instead, the flow may become
turbulent which easily permits humid air to contaminate the gas stream.

High humidity means that the amount of water vapor or moisture in the air is very high. As a
result, humid air contamination can cause more severe porosity than similar contamination of the
gas stream by relatively dry air. In manual welding, the arc length varies depending upon the
welder’s skill and the opportunity for contamination from the atmosphere is always possible.

The oxide layer on the surface of aluminum is always growing in thickness even at room
temperature. This oxide is a dull color and it is porous. In fact, the oxide layer acts like a
sponge and absorbs moisture from the air as well as oil, grease, and dirt from the surrounding
shop. If these faying surfaces are not adequately cleaned before welding, porosity will develop
in the aluminum weld metal.

The purity and quality of welding-grade shielding gases are governed by the specification from
the American Welding Society, AWS 5.32, as shown in Table 1. This specification not only
provides an identification system for shielding gases, but also, it specifies required purity and
dew point for individual gases. For example, the required maximum dew point temperature for
pure argon is -60°C (-76°F) and the minimum purity of argon gas is 99.997%. The dew point is
the temperature below which moisture (impurity) in gas begins to condense into droplets of
water. So, argon having a high dew point will contain a large volume of moisture, whereas
argon having a low dew point temperature will contain very little water.

Table 1 Purity and Dew Point of Common Shielding Gases per AWS A5.32

Minimum Maximum Dew Point AWS

Purity (%) Moisture (ppm) Maximum Classification

Argon 99.997 10.5 -60°C (-76°F) SG-A

CO2 99.8 32 -51°C (-60°F) SG-C
Helium 99.995 15 -71°C (-57°F) SG-He

AC Power to Weld Aluminum

For most hand-held GTAW applications, AC power is used for the very practical reason of oxide
removal or “cleaning action”. If GTAW with DC power is used on aluminum, which has not
been chemically and/or mechanically cleaned immediately before welding, the thick and porous
oxide layer of Al2O3 can have a detrimental effect on both integrity and code-acceptability of the
joint. DC welding of aluminum is covered in the next section.
When welding aluminum alloys for both flat and out-of-position GTAW, a strong cleaning
action is achieved by using AC power and DC-EP. Although other materials like steel may
experience a small cleaning effect when welding with electrode positive, the cleaning action in
aluminum is so strong that welding procedures depend upon on it for code work. The reason
why this cleaning effect takes place only when the electrode is positive is not fully understood.
The cleaning action is possibly due to the presence of the thick refractory Al2O3 oxide layer
protecting the aluminum acts as a capacitor. During GTAW, electrical charge builds up below
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and above the oxide layer, which is an electrical insulator. When the Al2O3 oxide layer has
accumulated sufficient electrical charge, the layer physically explodes leaving a clean surface
protected by the argon shielding gas. This action not only takes place above the melting point of
aluminum (660°C) but also well below its melting point. In fact, the heat-affected zone of the
aluminum weld is usually completely cleaned by this action. This dynamic cleaning action is
clearly visible by the welder during the GTAW operation. After the weld is finished, the weld
and heat-affected zone areas are smooth and brightly cleaned.

DC-EP Current to Weld Aluminum

Since the cleaning action occurs only during the DC-EP part of the AC cycle, why not used DC-
EP exclusively, as it is for GMAW? The great advantage of GTAW of aluminum with DC-EP is
the maximum possible cleaning effect. Unfortunately, 70% of the heat generated by the arc in
GTAW is delivered to the tungsten electrode when using DC-EP. This results in “spitting” and
melting of the tungsten electrode at very low current settings. Furthermore, weld penetration
with DC-EP is very shallow. Thus, the only limited used of DC-EP is for welding thin sheet,
where the current is low enough to prevent melting of the tungsten electrode. Using a larger
diameter electrode is also helpful in keeping the tungsten electrode from melting.

DC-EN Current to Weld Aluminum

Although the great majority of GTAW is conducted using AC power, aluminum can be welded
with DC-EN current using 100% helium and thoriated tungsten electrodes. The disadvantage of
DC-EN current is the total absence of cleaning action. The great advantage of GTAW with DC-
EN current is the substantial increase in penetration. DC-EN has become particularly beneficial
for automatic GTAW of thick aluminum plate. A further advantage is that smaller diameter
electrodes can be used, because only 30% of the heat is used to heat the tungsten electrode with
DC-EN.

Compared to AC welding, DC-EN can provide a deeper and narrower weld pool. Unlike AC
welding, preheating of thicker aluminum sections is not necessary. In addition, less edge
preparation is needed and the groove can be reduced in size so that less filler metal is consumed.
Since the heat intensity is greater with DC-EN, the weld pool is formed faster resulting in less
distortion of the base metal than with AC. Not only does DC-EN have substantial advantages for
GTAW thick aluminum plate, but also DC-EN can also be used for welding thin aluminum at
significantly faster travel speeds than with AC.

Pure Tungsten vs Zirconiated Electrodes

When welding with DC-EP or DC-EN, thoriated tungsten electrodes (EWTh-1 or EWTh-2) are
always used. However, when GTAW of aluminum with AC current, it is important that the tip
of the electrode have a hemispherical shape for better arc action. Both pure tungsten (EWP) and
zirconiated tungsten electrodes (EWZr) are used for GTAW with AC power. The addition of
zirconium oxide to tungsten (EWZr) electrodes provides several advantages over pure tungsten
electrodes. The zirconiated electrodes are capable of higher electron emissivities because the
zirconium oxide is a better thermionic emitter than pure tungsten. As a result, zirconiated
electrodes produce higher welding currents without spitting. Because the thermionic emission
temperature for EWZr electrode is lower than that for EWP, a more stable arc can be achieved
by using zirconiated electrodes especially of thicker section AC welding.

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 Welding Vocabulary

Name: _______________________________ Date: _________________________

Directions:
Define the following terms. Use Welding Principles and Applications or the text books in the
Welding Resource Room (Bldg 2/132a) to define these terms.

Welding Positions

1F

2F

3G

4G

Flow Meter

Inert Gas

Surface Tension

Arc Length

Porosity

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Travel Angle

Work Angle

Heat Treatment

Ionization Potential

Balled Tungsten

Alloy Elements

Casting (Aluminum)

Wrought (Aluminum)

1XXX (Aluminum)

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Thermal Expansion

Ductility

Malleable

High Frequency

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 GTAW EQUIPMENT AND CONSUMABLES
Name: _______________________________ Date: _________________________

Directions:
Define the following terms. Use Welding Principles and Applications, WLD 222, Training
Packet Information Sheets, or the text books in the Welding Resource Room (Bldg 2/132a) to
answer these questions.

1. What does ACHF mean?

2. Why is pure tungsten the choice for welding Aluminum?

3. How is the tungsten prepared for welding Aluminum?

4. What is the purpose of continuous high frequency in GTAW of Aluminum?

5. What determines the size of the tungsten electrode?

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6. What factor determines the type of current to be used?

7. What type of output does the power source you are using have?

8. How are TIG torches cooled? Why is it necessary?

9. What part of the torch assembly conducts current to the tungsten?

10. List two functions of the "collect body."

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 GTAW of ALUMINUM
The purpose of this project is to give the student hands-on practice in GTAW of Aluminum.
This
project includes all the GTAW tasks you will be required to do in this section. Each project
required
is presented by a schematic drawing. The drawings have all the information needed to complete
the
welding exercises. All welds must conform to the standard as interpreted by the instructor.

If the metal thickness specified is not available, you may use any thickness of metal that is
appropriate. The drawings are not made to scale. Dimensions other than those stated will be
acceptable if you can justify the use of material.

It is your responsibility to keep this packet and see that the instructor signs off all welds that you
complete. If you complete a project that you think is satisfactory and the instructor is not readily
available, proceed to the next project. Be sure to keep completed welds until they have been
inspected and signed off by the instructor.

SAFETY RULES

1. Wear long sleeves! Coveralls or a heavy cotton shirt is recommended to avoid a painful
arc burn to the skin.
2. Wear gloves! A light weight, soft, leather glove is most comfortable for easy handling of
small filler rods.
3. Ankle high leather boots are required in the welding shop regardless of welding process
being used. NO EXCEPTIONS!
4. Safety glasses are required at all times in the welding shop.
5. Welding shield with suitable filter lens (shade #10 or darker) is recommended. Check
your shield for any leaks or cracks.
6. A full face shield will be used when grinding.
7. No hand grinders permitted on or near T.I.G. machines.
8. Keep all clothing and gloves dry to insulate you from possible electrical shock.
9. Do not weld on tanks, drums, or closed containers.
10. Remove all fire hazards from the weld area.
11. Do not place any metal on T.I.G. machines. This includes filler rods.
12. Do not use pedestal grinders to prepare aluminum. This is extremely dangerous and
could cause the wheel to explode. Check out the Aluminum disc grinder from the tool
room. Protective guards must be on disc grinders. Wear a face shield!
13. Shield others from light rays produced by your welding arc.
14. To avoid machine damage, never change the polarity switch or amperage control while
machine is under a welding load.

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 SHOP RULES
1. Observe all safety rules and safe shop practices.
2. T.I.G. filler will be consumed to a maximum stub length of 3 inches.
3. Tungsten electrodes will be used to a maximum stub length of 1-1/2 inches.
4. Obtain T.I.G. torch assembly from cabinet in the TIG area.
5. Personal projects will not be permitted unless first authorized by your instructor and a
work order approved.
6. Do not attempt to repair equipment. Report the problem to your instructor or the tool
room person.
7. Unauthorized visitors will not be permitted in the shop.
8. Do not weld or tack materials to the table tops, stanchions, or clamps.
9. Horseplay and throwing of metal or equipment will not be tolerated.
10. All students are required to use the time clock. See your instructor if you cannot find
your time card.
11. Stay at your work station. This is where you receive individual instructions. Your
instructor will make "rounds" visiting each student at their work stations. If you are
having a problem, try to identify it, list questions on your work sheet to be discussed with
your instructor. Review your information sheets and continue practice. Keep the work so
your instructor can analyze it with you.

CLEAN UP PROCEDURES

1. All welding will stop 10 minutes prior to the end of shift.

2. All items checked out will be returned to tool room.
3. All aluminum scrap will be placed in the "aluminum only" bin.
4. All filler stubs will be placed in yellow bins.
5. Return any unused filler metal to the TIG cabinet.
6. Any unused prepared metal may be stored in your locker for the following day's use.
7. Torch and foot control will be coiled and stored on top of welding table.
8. Work station will be thoroughly swept.
9. Machine will be turned off when not in use.

NOTE : Good work habits and safe shop practices are as much of a requirement in the
industry as are your welding skills.

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 WELDING PROJECTS
The GTAW exercises you will be required to do are detailed in this section. Each project
required is represented by a Blue Print and recommended welding procedure. If metal thickness
specified is not available, you may use any thickness of metal that is appropriate. Dimensions
other than those stated will be acceptable if you can justify the use of material. It is your
responsibility to keep this packet and to see that the instructor signs off all welds that you
complete. If you complete a project that you think is satisfactory and the instructor is not readily
available, proceed to the next project. Be sure to keep each weld that is completed until your
instructor inspects the weld and signs it off.

An important part of your training is to develop skills in assessing your welds. You need to be
able to recognize weld defects and identify both the cause for the defect and what corrective
steps to take. The welding project sheet requires that you assess the completed project prior to
submitting it for final inspection by the instructor.

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 Set Up Procedure for Welding Aluminum
Material preparation
Cleanliness of material is a critical factor of success in GTAW. All surface contamination must
be removed. Use a wire brush to loosen the surface oxides on Aluminum.

You will need

• EWP - (size selected according to material thickness and current range, available in sizes
1/16”, 3/32”, and 1/8”).
• Collet - same size as tungsten.
• Collet holder - same size as tungsten.
• Ceramic cup - size will vary with joint type and tungsten diameter.
• Filler metal

Tungsten Preparation
A "balled" or rounded taper is used for welding aluminum. This is done because it allows for a
wider cleaning action during welding.

During the reverse polarity half cycle of the A.C., the ionization of the gas bombards the weld
surface. Direction of current flow during the reverse polarity half cycle is from the work (-) to
the electrode (+). This direction of flow lifts the oxides from the weld surface, resulting in the
"cleaning action."

The ball my be formed in two ways:

A. Increasing the amperage range to the maximum recommended for the tungsten diameter
and initiating the arc will cause the tungsten to consume itself forming the rounded tip.
Too much amperage will cause the ball to enlarge or melt off. Vibration of the ball and
enlarging of the ball are indications that the current range is too high for the electrode
diameter, or the electrode is too small for the current required.

The ball on the tip of the tungsten should not exceed 1-1/2 times the tungsten
diameter. The smaller the ball the better because this helps focus the arc.
B. The ball my also be formed by adjusting the polarity switch to DC + DCRP (Direct
Current Reverse Polarity) and initiating an arc. In critical applications this is sometimes
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 done on a clean copper bar to avoid contamination of the tungsten. The condition of the
tungsten is an important factor in successful weld results. If the tip becomes
contaminated during welding, the contaminated portion should be broken off and the tip
redressed.

• Ball Tungsten Grind to a point using the grinder designated for tungsten only in GTAW
area. Do not grind the end with the red band on it.

Torch Assembly
• Loosen cap of torch until "0" ring is visible.
• Insert tungsten in collet and collet into collet holder. Screw this assembly into
front of torch, finger tight only.
• Screw on ceramic cup and adjust tungsten stick out (the distance the tungsten
extends beyond the cup). Tungsten stick out will vary with joint type. Stick out should be
long enough to insure proper arc length but should not exceed your cup diameter to
insure proper shielding
• Tighten torch cap to secure tungsten position finger tight only.
Machine Adjustment
• Polarity switch should be set on alternating current with high frequency on continuously
(ACHF).
• Current range is adjusted by setting coarse adjustment and fine adjustment
according to electrode diameter, material thickness and weld joint requirement.
• Remote/Standard switch - set on remote.
• Post flow timer adjusted to sufficiently shield tungsten and weld crater.
• High frequency switch should be in continuous or “on” position.
• Turn power switch on.
• Turn on gas and water supply at service lines.
• Depress foot control to initiate gas flow and water (if water cooled torch).
• Make sure torch is not in contact with grounded surface or it will arc. Set gas flow rate at
10 - 15 c.f.h. by adjusting knob on flow meter. Check water return line to see that water
is flowing.
• Test machine adjustments on a piece of scrap.

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 Craftsmanship Expectations for Welding Projects
Your instructor will be evaluating your welding projects by the following standards. Read carefully
and apply these standards to your project before asking for the instructor's approval.

Steps in completing welding projects:

1. Thoroughly read each drawing.
2. Utilize scrap material to adjust machine.
3. Assemble the welding projects per drawing specifications.
4. Review the Welding Procedure portion of the prints to review welding
parameter information.
5. Complete welding project. Practice as needed to meet acceptance criteria
listed below.
6. Complete the student assessment piece on the project sheet.
7. Submit project to the instructor for the final grading.
Factors for grading welding projects are based on the following criteria
Metal Preparation Project Layout Weld Quality
Thoroughly clean metal Correct joint assembly See chart below
(+/- 1/16”)

Weld Quality per AWS D1.1

VT Criteria Cover Pass
Weld Size See specification on drawing
Undercut 1/32” deep
Weld Contour Smooth Transition
Penetration N/A
Cracks None Allowed
Arc Strikes None Allowed
Fusion Complete Fusion Required
Porosity None Allowed
Overlap None Allowed

Example of a High Quality Weld

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GTAW Flat Position Edge Joint (Autogenous/Fuse Weld) Project #1

Objectives of this welding exercise are:

• To learn how to set up and adjust the equipment.
• To develop your ability to control travel speed and arc length.
• Your goal is to fuse the edge surfaces resulting in a smooth rounded contour on all sides of the
joint. Note that when “fuse” welding no filler material is added.
Cause and effect factors
Amperage
Too high = undercutting
Too low = lack of fusion on the edges of the joint
Travel Speed
Too slow = excessive heat, irregular shape, burning away of the edge
Too fast = weld does not wrap the edges of the plates leaving them sharp and jagged.
Arc length
Too short = touching the tungsten to the work, contaminating the tungsten and the work.
Too long = undercutting, and can result in loss of gas coverage creating porosity.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Flat Position Corner Joint (Autogenous/Fuse Weld) Project #2

Objectives of this welding exercise are:

• To practice set up and adjustment of the equipment.
• To develop consistency in control of travel speed and arc length.
• Your goal is to fuse the edge surfaces resulting in a smooth rounded contour on all sides of the
joint. Note that when “fuse” welding no filler material is added.
Cause and effect factors
Amperage
Too high = undercutting, or melting holes through the work
Too low = lack of fusion on the edges of the joint
Travel Speed
Too slow = excessive heat, irregular shape, burning holes
Too fast = weld does not wrap the edges of the plates leaving them sharp and jagged.
Arc length
Too short = touching the tungsten to the work, contaminating the tungsten and the work.
Too long = undercutting, and can result in loss of gas coverage creating porosity.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Flat Position Butt Joint
Project #3

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Flat T Joint Project #4

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Horizontal T Joint Project #5

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Horizontal Lap Joint Project #6

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Horizontal Corner Joint Project #7

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Horizontal Butt Joint Project #8

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Vertical T Joint Project #9

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Vertical Lap Joint Project #10

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Vertical Position Corner Joint Project #11

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Vertical Position Butt Joint Project #12

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Overhead Position T Joint Project #13

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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GTAW Overhead Position Lap Joint Project #14

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed Grade

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GTAW Overhead Position Butt Joint Project #15

Objectives of this welding exercise are:

• To practice set up and adjust of the equipment for a different application.
• To develop consistency in your ability to control travel speed and arc length.
• To develop the ability to add filler material to the weld pool.

VT Criteria Student Assessment Instructor Assessment

Weld Size
Undercut
Weld Contour
Penetration
Cracks
Arc Strikes
Fusion
Porosity
Overlap
Completed GRADE

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Final Exam
Part One
This portion of the final exam is a closed book test. Consult with your instructor to determine items
that you may need to review. Once you determine that you are ready for the exam, request it from
your instructor. Complete the exam and write all answers on the answer sheet. Once completed,
return the exam to your instructor for grading.

Part Two
This portion of the exam is a practical test where you will fabricate and weld a weldment from a
“blue print.” The evaluation of this portion of the exam will be based on the rubric. You will have
two class periods to build the project.

WLD 222 2017 94

NSF Project - Advanced Materials Joining for Tomorrow’s Manufacturing Workforce
WLD 222 2017 95
NSF Project - Advanced Materials Joining for Tomorrow’s Manufacturing Workforce
WLD 222 GTAW Aluminum: Project Assessment Form
Student Name:________________ Date_________

Flat Position Assessment Instructor Signature/Date
Edge Joint – Fuse Weld
Corner Joint – Fuse Weld
Butt Joint
T-Joint

Horizontal Position Assessment Instructor Signature/Date
T-Joint
Lap Joint
Corner Joint
Butt Joint

Vertical Position Assessment Instructor Signature/Date
T-Joint
Lap Joint
Corner Joint
Butt Joint

Overhead Position Assessment Instructor Signature/Date
T-Joint
Lap Joint
Butt Joint












Final Grading Rubric for practical exam
Class Name: WLD 222
Name: ________________________________ Date: _______________________
Hold Points are mandatory points in the fabrication process, which
require the inspector to check your work. You are required to follow
the hold points.
Points Hold Points Instructor’s
Possible Evaluation

5 points Blueprint Interpretation and Material Cut List
5 points = 0 errors, all parts labeled and sized correctly
3 points = 1 error in part sizing and/or identification
2 points = 2 errors
1 point = 3 errors
0 points = 4 or more errors
10 points Material Layout and Cutting (Tolerances +/- 1/16”)
10 points
Layout and cutting to +/-1/16”
Smoothness of cut edge to 1/32”
7 points
Layout and cutting to +/- 1/8” Smoothness of cut edge to 1/16

REWORK REQUIRED IF OUT OF TOLERANCE BY MORE THAN 1/8 INCH
10 points Fit-up and Tack weld (Tolerances +/- 1/16”)
10 points
Tolerances +/- 1/16”
Straight and square to +/-1/16”
7 Points
Tolerances +/- 1/8”
Straight and square to +/-1/8”
REWORK REQUIRED IF OUT OF TOLERANCE BY MORE THAN 1/8 INCH
15 points Weld Quality
Subtract 1 point for each weld discontinuity,
incorrect weld size and incorrect spacing sequence.
28 points Minimum points acceptable. This equates to the
minimum AWS D1.1 Code requirements.
Total Points /40