goggles or safety glasses with side shields and pro
tect the hands and other exposed parts of the body
with protective garments, or if possible, work with a
shield between the body and the work piece.
The intense heat produced at the arc sets up strains
in the metal joined by welding. Peening the weld not
only removes the scale left behind in the welding but
relieves the internal strains developed by the heating
and cooling process.
4. TIG welding skill
Gas Tungsten Arc Welding (GTAW) or TIG (Tungsten
Inert Gas) as it is commonly referred to, is a weld
ing process in which fusion is produced by an elec
tric arc that is established between a single tung
sten (nonconsumable) electrode and the work piece.
Shielding is obtained from a welding grade shielding
gas or welding grade shielding gas mixture which is
generally Argon based. A filler metal may also be
added manually in some circumstances depending
on the welding application.
Tungsten Electrode Current Ranges
Electrode Diameter
0.040" (1.0 mm)
1/16" (1.6 mm)
3/32" (2.4 mm)
1/8" (3.2 mm)
5/32" (4.0 mm)
3/16" (4.8 mm)
Guide for Selecting Filler Wire Diameter
Filler Wire Diameter
1/16" (1.6 mm)
3/32" (2.4 mm)
1/8" (3.2 mm)
3/16" (4.8 mm)
29
DC Current (Amps)
30-60
60-115
100-165
135-200
190-280
250-340
DC Current Range (Amps)
20-90
65-115
100-165
200-350
Tungsten Electrode Types
Electrode
Welding
Type
Application
(Ground
Finish)
Thoriated
DC welding of mild
2%
steel, stainless steel
and copper
Zirconated
High quality AC
1%
welding of aluminium,
magnesium and their
alloys.
Ceriated
AC & DC welding of
2%
mild steel, stainless
steel, copper, alumini-
um, magnesium and
their alloys
Aluminium Welding Material
Base Metal
AC Current
Thickness
for Aluminium
1/16"
6080
1.6 mm
7090
1/8"
125145
3.2 mm
140160
Filler Rod Diame-
Argon Gas
ter (if required)
Flow Rate
1/16"
7 l/min
1.6 mm
1/16"3/32"
8 l/min
1.6 mm 2.4 mm
Welding Rate
Base
DC Current
Metal
for Mild
Thickness
Steel
0.040"
3545
1.0 mm
4050
0.045"
4555
1.2 mm
5060
1/16"
6070
1.6 mm
7090
1/8"
80100
3.2 mm
90115
3/16"
115135
4.8 mm
140165
1/4"
160175
6.4 mm
170200
Features
Color
Code
Excellent arc starting,
Red
Long life. High current
carrying capacity
Self cleaning. Long
White
life. Maintains balled
end. High current
carrying capacity.
Longer life, More stab-
Grey
le arc, Easier starting,
Wider current range,
Narrower more
concentrated arc.
Tungsten Elec-
trode Diameter
1/16"
1.6 mm
3/32"
2.4 mm
Joint Type
Butt/Corner
Lap/Fillet
Butt/Corner
Lap/Fillet
DC Current
Tungsten
for Stainless
Electrode
Steel
Diameter
2030
0.040"
2535
1.0 mm
3045
0.040"
3550
1.0 mm
4060
1/16"
5070
1.6 mm
6585
1/16"
90110
1.6 mm
100125
3/32"
125150
2.4 mm
135160
1/8"
160180
3.2 mm