20

Gas Tungsten Arc

Welding Practice:
Jobs 20-J1J17 (Pipe)

After you have mastered the gas tungsten arc welding of Chapter Objectives
commercial metals and their alloys in the form of plate,
you may gain further skill in the process by practic-
After completing this chapter, you will be able to:
ing on pipe. Gas tungsten arc welding produces welds
in pipe that are unusually smooth, fully penetrated, and 20-1 List the advantages for the GTAW process for pipe
free from obstructions and crevices on the inside. These welding.
welds have maximum strength and are highly resistant 20-2 Describe the joint designs associated with GTAW
to corrosion. on pipe.
The process may be used to weld both ferrous and non- 20-3 Describe proper techniques for making tack, root,
ferrous piping materials. It is a highly desirable process filler, and cover pass welds.
for the welding of nonferrous materials. 20-4 List causes of porosity in GTAW welds.
Gas tungsten arc welding is used in the fabrication 20-5 Produce acceptable weld beading on pipe.
of aluminum, stainless-steel, nickel, nickel alloys, and
20-6 Produce acceptable groove welds on steel, stainless
alloy steel piping. See Figs. 20-1 and 20-2. For tem- steel, and aluminum pipe in all positions.
peratures above 750F and for power plant work, low
alloy steel pipe containing small amounts of chromium
and molybdenum is used. Stainless-steel piping is used
for high and low temperature work, for chemical and
process piping, and in those situations in which the
pipe must resist corrosive chemicals. Copper, nickel,
and their alloys are selected for resistance to chemi-
cal attack, especially by saltwater. Aluminum pipe has
the advantages of being light in weight, resisting corro-
sion, and not forming toxic chemicals in the processing
of food and drugs. The GTAW process has applica-
tion in the welding of nuclear piping systems, reactor

630

Fig. 20-1 An A106B pipe of 2-34 inch O.D. and a wall thickness of 58
inch in the 6G position. For a welder qualification test coupon, this can
save 80% of the weld time and material vs. a 6inch O.D. double extra
heavy pipe coupons. This coupon will qualify for unlimited thickness and
diameters as small as 1 inch O.D. using two weld processes. Such as
GTAW on the root and filling half the joint and SMAW for the remainder
of the joint. When welded in accordance to the current ASME Section IX
requirements. The purge set up may or may not be required, a lways fol-
low the welding procedure. Renee Bohnart
Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20631
vessels, and their auxiliary vessels. In these applica-
tions it is necessary to contain radioactive fluids under
high pressures at both low and high temperatures. Joint
tightness and cleanliness are absolutely essential be-
cause of the dangers of radioactive contamination.
Substantial quantities of carbon steel pipe are welded
with the gas tungsten arc process for the root pass only.
The thinnest section that can be manually welded is
approximately 132 inch. For pipe wall thicknesses from
to 38 inch, it is generally more economical to complete
the pipe weld, after the gas tungsten arc root pass, with
the gas metal arc or submerged arc process. The shielded
metal arc welding or flux cored arc welding process may
also be used. Some type of gas or metal backing improves
the quality of the weld and makes the job of the welder
somewhat easier.
Accurate joint preparation and good fitup are essential.
Cleaning in preparation for welding must be carefully
performed, and in some cases the base metal may require
chemical treatment. Some type of gas or metal backing
improves the conditions for welding. Welding may be
done in all positions.
Joint Design
The following information may be applied to the
welding of steel, aluminum, and stainless-steel pipe.
Five basic joints are in general use in the gas tungsten
Fig. 20-2 Welding on aluminum pipe,
in the 1G pipe rotated position. The weld-
ing machine is a 300-ampere a.c.-d.c.
enhanced square wave GTAW power
source. Renee Bohnart
arc welding of pipe. Selection of a particular design the close control of dimensions and fitup needed to produce
depends on the type of material, the thickness of the satisfactory results.
material, and the nature of the installation. It is rec-
ommended that all pipe with a wall thickness of more Joint Preparation
than 18 inch be beveled to ensure sound welds. When pipe is of such thickness that beveling is necessary,
it should conform to the specifications given in Figs. 20-3
Standard V-Groove Butt Joint through 20-6 and Table 20-1. All beveling should be done
The V-groove, Fig. 20-3, with the 75 groove angle and a by machine. Grinding may deposit impurities on the sur-
root face of 116 inch is considered standard. On noncritical face of the metal, which contaminate the completed weld
jobs the joint may be butted together and welded without and make the welding operation more difficult. Prevention
a filler rod on the root pass. Code quality welding requires of surface contamination is especially important when
that the joint be spaced at the root from 116 to 332 inch as welding aluminum pipe.
shown.
Backing or Purging
371/2
Sharp V-Groove In order to obtain the smooth interior surface specified in
Butt Joint Fig. 20-7 and shown in Figs. 20-8 and 20-9, page 634 it
is necessary to protect the back as well as the face of the
This joint, Fig. 20-4, does
weld bead from oxidation. This may be done by introduc-
not have a root face like the
ing argon or helium into the pipe. This operation is known
/
1 16 / to 3/32
1 16 standard V-groove. It can be
as purging. The gas shields the molten pool on the inside
prepared by cutting with an
of the pipe. It should flow at a rate of about 6cubic feet per
Fig. 20-3 Standard V- oxyacetylene cutting torch.
groove butt joint. minute during the welding operation. Carbon steel and alu-
The root pass must be welded
minum do not typically require purging; verify by review-
with filler rod.
371/2
ing the welding procedure.
A fixture similar to that shown in Fig. 20-10 (p. 634)
U-Groove Butt may be used for purging. This fixture can be made with
Joint materials usually found in the school welding shop, and it
The U-groove joint, Fig. 20-5, may be fabricated and welded by the students.
is used when uniform welds of The conical pipe inserts D and E may be made with
high quality are required. This any desired diameter. They will fit all sizes of pipe up to
Fig. 20-4 Sharp V-groove
butt joint. joint is particularly adaptable the maximum diameter of the cone at its largest end. The
to position welding because it cone D is welded to the tube and is fixed while cone E
is possible to obtain complete is adjustable by slipping the clamp F along the tube H in
30 / R
3 16

and uniform penetration. Root order to adjust to various lengths of pipe.

passes should be made with
filler rod, although good pen-
/ to 3/32
1 16
etration can be secured with- / Weld Melt Through
1 32

out it.
Fig. 20-5 U-groove butt
joint. Consumable Insert
Butt Joint
30 Penetration
/
1 16 This type of joint, Fig. 20-6, Bead Width
18 / R produces welds of the highest 1/8 Minimum

quality to specification. The / Maximum

14

insert may be thought of as a

ring of filler metal, which may
1 16/
0.055 have a special composition to 1/32 Maximum Concave Root
/
5 32
prevent porosity and to enable
Surface in Overhead Position
Fig. 20-6 Consumable the weld metal to meet specific
insert on U-groove butt requirements. A disadvantage Fig. 20-7 Specification for penetration bead contours in a stan-
joint. of the consumable insert joint is dard V-groove butt joint.

632Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)

 Table 20-1 Joint Preparation for the Welding of Pipe with the Gas Tungsten Arc
Welding Process

Type of Position of No Backing With Backing Type of Gas Bevel Bead Root Root
Material Welding Ring Ring Shielding Angle1 Face2 Opening3
Aluminum 2&5 x Helium 3712 1
16 None
Aluminum All x Helium 37 2
1 1
16 3
16
Aluminum 5 bottom only x Helium 60 1
16 None
Aluminum 1 x Argon 3712 1
16 1
16
Aluminum 2&5 x Argon 55 1
16 1
16
Aluminum 1 x Argon 37 2
1 1
16 3
16
Aluminum 2&5 x Argon 55 1
16 3
16
Steel &
stainless steel
1
16 to
5
32 thick All x Argon None Total 1
16
All x Argon None Total 1
8
5
32 to
1
4 thick All x Argon 3712 1
16 3
32
All x Argon 3712 1
16 3
16
1
Bevel angle may be 2 2.
1

2
Root face may be 132 inch.
3
Root opening may be 116 inch.

The nut adjustment B permits positioning of the weld
at any point around the circle. The pipe support C may be
inserted into a larger fixed pipe in a stand, or it may be
attached to the welding table so that the height of the unit
can be adjusted. The purging gas passes from a flow valve
through the welding hose A and into the tube which is
plugged at the far end. This forces the gas to flow through
the gas outlet holes G in the tubing and inside the pipe
joint for purging.
In order to be able to weld under the most favor-
able of conditions, some kind of pipe-rotating device
is necessary for the rolled-position welds. Figure2011
(p. 634) illustrates a manually operated unit that may
be made quickly in the school shop. The gas-purging
unit for the pipe interior, shown in Fig. 20-10, may
also be a ttached to the rotating unit. This unit
may be driven by an electric motor having a
control unit with a speed control range up to
10r.p.m.
The inside of the pipe may also be protected
by painting with the proper flux. Welds backed
up by flux are high quality, and they are al-
most equal in physical properties to those made
with gas purging. Flux permits more penetra-
tion through the back side, whereas gas purg-
ing reduces the inside buildup and causes a very
smooth inside bead.

Fig. 20-8 The underside of a root pass in steel pipe welded with the gas
tungsten arc welding process. Filler metal has been added. The joint shows
complete penetration free of notches, icicles, crevices, and other obstructions to
flow. Reinforcement is between 132 and 332 inch.
Tack Welds
Tack welds are used to hold the sections of pipe
together in preparation for welding. In pipe
welding by the gas tungsten arc process, tack

Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20633

Fig. 20-9 The back side of a root pass in stainless-steel pipe. This is the
inside of the pipe.
B D
A C
Fig. 20-10 Conical fixture used for purging the inside of piping and tubing. This can
be made in the school welding shop.
If filler rod is to be used for the root pass,
you should use filler rod for the tack weld. Tack
welds should be about 1 inch long. Four to six
tacks per joint, depending on the pipe size,
should be spaced evenly around the pipe. Too
large a tack weld interferes with the weld that is
to follow. If the torch is withdrawn too rapidly,
the tack weld will crack.
When the root pass is welded, the tack weld
must be re-fused and become a part of the
weld. To aid in this, the beginning and end of
the tack weld should be filed or ground with
a cutting disk, starting approximately
3
8 inch from the edge and tapering to a
G E F feathered edge, as shown in Fig. 20-12.
This will allow proper fusion when com-
ing off a tack weld or when approaching
the tack weld.
In some critical applications the tack
welds are completely removed. This
requires the root pass to be stopped
slightly before the tack weld is reached.
The tack weld is then removed and the
root pass is continued until the next
H tack weld is encountered, and the pro-
cedure is repeated until the root pass is
complete and all tack welds have been
removed. Care must be taken when re-
moving the tack welds so as not to alter
the original joint design. Another tech-
nique is the use of bridge tack welds. This prevents
any issues in the root of the joint from the tack welds.
They are removed as the root pass is made around the
joint, Figs. 20-13 and 20-14.
Vent Holes
Argon
Discharge
Holes

Grind and Feather

Tack Welds

Argon Supply

Fig. 20-11 Pipe-rotating and purging device. /

38

/
38

welding must be done with care and skill because poor

tacks are often the cause of defects in the final weld.
Inert gas purging or flux is applied inside the pipe, and
the tack is made as small as possible. The torch is drawn
to the side of the bevel until the pool diminishes in size, Fig. 20-12 Properly prepared tack welds to allow for proper
and then the arc is broken. fusion. Edward R. Bohnart

634Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)


Fig. 20-13 Bridge tacks being used on a 4-inch Schedule 80, V-
groove butt joint on carbon steel pipe. Note the careful joint prepara-
tion prior to tacking. Edward R. Bohnart
Fig. 20-14 Another form of bridge tacks being used to support
large diameter heavy wall pipe and elbow as they are being posi-
tioned for welding. These bridge tacks will be evenly spaced around
the pipe. McGraw-Hill Education/Mark A. Dierker, photographer
Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20635
Porosity in Gas Tungsten Arc Welds
It is important at this time to call your attention again to
the matter of porosity in weld metal. There are two main
causes: (1) that resulting from the composition of the base
metal, and (2) contamination from the surface of the joint
or from the surrounding air.
Base Metal Porosity
Some steels contain iron oxides that react with the car-
bon in the steel during welding to release carbon mon-
oxide and carbon dioxide. These gases cause porosity in
the weld. Gas formation can be controlled by the use of
deoxidizing filler rod.
Porosity from Contamination
Contamination may be caused by iron oxides on the joint
surface or filler rod. Heavy rust or scale on the surface
produces a condition like that produced by oxides within
the material. Therefore, rust and scale inside and out-
side the pipe should be removed for a distance of at least
2 inches on each side.
Oil, grease, and moisture on the joint surface or filler
rod also contaminate the weld. These materials vaporize
when heated and produce gases that may be trapped in
the weld and cause porosity. All surfaces must be cleaned
with care.
Porosity may also result from atmospheric contamina-
tion. Inadequate gas shielding leaves the weld pool open
to attack. Inadequate shielding has the following causes:
Gas flow that is too slow
An arc that is too long
Too much electrode extending beyond the end of the
gas cup
Air currents in the work area
Practice Jobs
The equipment needed is the same as that used for the gas
tungsten arc welding of plate, Fig. 20-15, p. 636.
Instructions for Completing
Practice Jobs
Complete the jobs listed in the Job Outline, Table 20-2,
page 652, as assigned by your instructor. Before you begin
a job, study the specifications given in the Job Outline.
After you have demonstrated that you are able to make
satisfactory welds in carbon steel pipe of various diam-
eters, you are ready to proceed with the other pipe jobs
listed in the Job Outline. These jobs are on aluminum and
stainless-steel pipe. The welding technique is similar to
that used in your earlier practice on plate.
 To Gas
Gas-Water Backing
Shutoff Valve Device
(Optional) (If Used)
Argon
Inlet Hose
Water Inlet Hose
Torch
Regulator and
Power Cable
Flowmeter
Adaptor

Power Cable
and Water
Pipe Return Hose
Workpiece
Water
Out Hose
Argon
Cylinders
Work
Clamp on
Worktable +
D.C.
Water
Welding
Supply Line
Generator
or
Rectifier
Drain
An a.c. welding power
supply is sometimes used.

Fig. 20-15 A typical gas tungsten arc pipe welding installation.

Practice on steel, aluminum, and stainless-steel pipe in
sizes ranging from 2 to 6 inches in diameter. You are ex-
pected to complete the jobs calling for mild steel pipe before
practicing with aluminum and s tainless-steel pipe. Welding
should be done in the rolled, horizontal fixed, and vertical
fixed positions. Use the same general welding techniques
you learned in Chapter 19 for metal of the same thickness.
The procedures used in welding these practice joints
in pipe are those that are practiced on the job. No single
point is overlooked in making sure that the procedure will
produce welds that are sound. Piping installations are
such that a weld failure would not only damage property
but also endanger the safety of human beings.
Study the various joint designs and weld procedures
carefully. The nature of the material, the size of pipe, and
the position of welding are the three important variables
that determine the joint design, the pass sequence, and
all that this implies. Quality welding requires close con-
trol. It is truly a scientific process that demands a great
deal of skill in its application.
It is highly important that students who feel they want
to specialize in pipe welding become highly proficient
in the gas tungsten arc welding of aluminum and stain-
less pipe, since it is extensively used for piping made of
these materials and alloys of steel.
Roll Butt Joint Groove Welds:
Jobs 20-J1J7
Root Pass Practice on pipe 4 to 6 inches in diameter. After
you have practiced stringer and weaved beading around the
outside of the pipe (Job 20-J1), begin practice on joints with
the standard V-joint (Job 20-J2). Prepare the edges as in-
structed in Fig. 20-3, page 632. Tack the pipe in about three
places with small tacks so that they do not interfere with
welding. Brush, file or grind, and clean tacks before pro-
ceeding with the welding. Set up the pipe so that it can be
purged with argon to protect the underside of the weld bead
and to assist in making a smooth bead. Flux may be used
instead of gas purging. A 2 percent thoriated-tungsten elec-
trode with a diameter of 332 or 18 inch is preferred for weld-
ing. It should be ground to a point as shown in Fig.20-16.
Point the electrode toward the center of the pipe,
Fig. 20-17. The arc length should be 132 to 116 inch long.
Be careful to manipulate the torch so that the tungsten
electrode does not become contaminated.
Start the arc halfway up the groove face approximately
centered in the area of the tack weld. Bring the weld
pool down the groove face onto the tack weld. The filler
rod can be preplaced in the tapered area of the prepared
tack weld. The filler rod can be cut on an angle so it lies

636Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)

 0.5 to 2
Times Diameter
/ D
15
D
Fig. 20-16 Correct electrode taper.
First Pass Roll Weld
Hold Torch Here Rotation
Fig. 20-17 Position of the torch for a rotational weld.
directly into the tapered tack weld. Play the weld pool on
the center of the tack weld. This breaks down the tack
weld, which is evident by a small birds-eye of silica,
which will dance rapidly in the center of the weld pool.
You have achieved full penetration, and it is time to move.
Dont delay. Excess heat is detrimental to the weld and
may lead to a concave root surface.
Try to weld from tack to tack to reduce the number of
starts and stops. Minimizing the number of starts and stops
will reduce the number of possible defects and is always a
good procedure to follow when welding. Check your fitup,
and begin welding the root pass on the tack where the least
amount of root opening is present. As you weld the pipe,
contraction forces will close up the root opening. So weld
the tightest root opening area of the joint first.
Weld the root pass with the stringer bead technique.
Start just below the 2 oclock position and weld upward
to the 12 oclock position. Rotate the pipe clockwise so
that the crater of the bead just deposited is just below the
2 oclock position. After making sure that the weld crater
is clean, continue welding as before.
The filler rod should be added almost tangent to the
pipe surface, and the torch should be slanted about 15 to
20 toward the rod with an arc length of about 116inch,
Fig. 20-18. When the pool increases to about 18 inch in
thickness, remove the rod and allow the pool to flatten
out. When penetration appears to be complete, as shown
by the shape of the pool, add more filler rod and advance
the weld. Hold the tungsten electrode perpendicular to the
Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20637
Fig. 20-18 The relative position of the torch and filler rod when
making a multi-pass rotational weld on a stainless steel flange to
heavy wall pipe butt joint. This is being done on a positioner. Note the
completed weld of the pipe to the T branch section, also the well-
organized tool board in the background. Team Industries, Inc.
surface of the work in all positions. Excessive angulation
may result in inadequate shielding and reduce control over
the reinforcement contour.
Another technique, rather than inserting and removing
the filler rod, is to keep it in place. This is done by laying
the filler rod in the joint tangent to the pipe. To facilitate
this, bend the filler rod to conform to the shape of the
pipe. If a 332-inch root opening is being used, a 18-inch di-
ameter filler rod would be appropriate for this technique.
Approximately one-third of the filler rod diameter should
be in the joint and two-thirds of the filler rod diameter is
exposed to the arc. A sharp V-groove with no root face
works best with this technique. This technique works
much like a consumable insert joint.
A fluid weld pool changes shape when certain condi-
tions are present. You should learn how to read the weld
pool by observing its changing contours as the associated
conditions of penetration and bead formation change.
When welding begins, hold the electrode stationary
and point it toward the center line of the pipe. Preheating
is done by moving the torch in small circles over the two
bevels. The pool continues to grow until sharp points are
formed on opposite sides of the weld pool at the bottom of
the V. When you see these points, advance the electrode
in a straight line. The sharp point on the leading edge of
the weld pool indicates whether or not the electrode is pro-
ceeding in a straight line. Figure 20-19 (p. 638) shows the
point formation after a portion of the pipe has been welded.
As long as this point formation is present, penetration is
being obtained on the inside of the pipe. If you advance the
electrode too rapidly, the point on the weld pool becomes
rounded, or it may even form a notch (re-entrant angle),