QIWS/001 - Tungsten Arc Gas Shielded Welding Tutor Pack EAL Level 1 Award in Introductory Welding Skills Unit: QIWS-001 – Tungsten Inert Gas Shielded Welding (TIG) Issue1.0
QIWS/001 - Tungsten Arc Gas Shielded Welding
Tutor Pack
EAL Level 1 Award in Introductory Welding Skills Unit: QIWS-001 – Tungsten Inert Gas Shielded Welding (TIG)
Issue1.0
QIWS/001 – Tungsten Inert Gas Shielded Welding - 2 -
Contents
Page
Section 1 : Introduction
3
Section 2 : Guidance on assessment
4
Section 3 : Self study pack
5
Section 4 : Welding procedure specifications and assessment sheets
17
Section 5 : Knowledge questions
27
Section 6 : Knowledge answers
30
Section 7 : Declaration of completion
33
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Section 1: Introduction This self study booklet is provided to support your learning and prepare you to complete the knowledge
questions provided. You should read this and complete it with support from your tutor and upon
completing the qualification you should retain the booklet as a useful resource about the welding
process you have completed. It also contains the Welding Procedure Specifications (WPS) that detail the
requirements of the 5 five practical tests you must attempt to complete the qualification.
During this qualification you will develop the practical skills required to perform Tungsten Inert Gas
Shielded Welding (TIG) welding in the flat and horizontal/vertical positions. You will produce welds and
visually assess that they are fit for propose against the requirements of the weld procedure (WPS)
provided within the unit internal assessment. Furthermore you will learn the fundamental underpinning
knowledge relevant to the TIG welding process including, safety, use of equipment and choice of
consumables.
This Qualification is intended to provide a level of knowledge that will allow fundamental welding to
take place safely and provide the base level of knowledge and skill to allow progression onto level 2
qualifications.
This booklet covers the six learning outcomes of the qualification:
Learning outcome:
Assessment method:
1. Produce beads on plate in the PA flat position
Practical task
2. Produce a lap fillet weld in the PB horizontal/vertical position
Practical task
3. Produce a tee fillet weld in the PA flat position
Practical task
4. Produce a tee fillet weld in the PB horizontal/vertical position
Practical task
5. Produce a corner weld in the PA flat position
Practical task
6. Know the Process and Health & Safety requirements of TIG welding
Knowledge test
All the assessments must be competed in line with the assessment guidance provided and signed off by your tutor. All work should be retained for inspection by the EAL External Verifier if requested.
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Section 2: Guidance on Assessment Guidance on the completion and assessment of the welds
1. All welding plate blanks to be at least 150mm by 50mm
2. All TIG welding tests to be completed using1.0 – 3.0mm Low Carbon Steel
3. All welds to be single run
4. No stop start requirements on tests (however it is recommended this is practiced)
5. All weld testing is visual only (however it is recommended macro etch is demonstrated)
6. All weld assessment must be recorded on the provided sheet and retained
7. Tasks should take no more than 45 minutes
Guidance on the completion of the knowledge questions
1. All questions must be attempted
2. This is an open book assessment
3. Any questions completed incorrectly must be discussed verbally with your tutor until they are satisfied you have understood
4. Answer sheets should be signed off and retained
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Section 3 : Self study pack
Learning Outcome 6: Know the Process and Health & Safety requirements of TIG welding
Process description:
A welding power source supplies a welding current to create an electric arc between a tungsten electrode and the surface of the metals to be joined.
This welding current can be set at a D.C. current for steel and stainless steel or an A.C. current for aluminum.
The arc is struck by using a high frequency charge and the tungsten electrode does not touch the surface of the metals to be joined. If it does it becomes contaminated and must be re-sharpened.
The heat of the arc melts the metal to form a molten weld pool.
An inert shielding gas is used to protect the weld from contamination; the gas is
released as the arc is initiated.
The welder manually adds a filler rod into the molten pool as welding progresses by dipping the filler rod into the molten pool. The quality of the finished weld is dependant how well this is done.
TIG welding is a skilled welding process that relies on a high level of manual dexterity.
It is particularly suitable for high quality welding on a range of aluminum and stainless steels. It is used extensively in the welding of aerospace, marine and food processing equipment. It also used to weld the root runs on multi process pipe welding.
Further information on TIG welding can be found at
http://www.twi.co.uk/content/jk6.html
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Health and Safety with TIG There are hazards associated with TIG welding. (Discuss each with your tutor and consider what actually causes the danger and how you can reduce the danger to your self and others whilst welding)
High Frequency
Arc Compressed
Gas Cylinders
Hot metal And
Burns
Fire and Explosion
WeldingFumes
and Noise
Arc Radiation
Electric Shock
Hazards
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!)
Personal Protective Equipment (PPE)
Protect yourself and others from Arc Radiation and Burns by wearing and using the correct PPE!
Wear the correct welding helmet with the correct grade of filter glass fitted (check it
Wear leather TIG gloves, welding overalls and steel toe capped boots in good serviceable condition
Exposure to welding arc can cause:
Skin burns like a very bad sunburn (ultra violet light) Fatigue and tiredness (infra red light) Arc eye (severe irritation to the eye –watering eyes and partial loss of vision), occurs 4-
8 hours after exposure and painful Beware of arc radiation from reflective surfaces Use screens around your work area to protect others
QIWS/001 – Tungsten Inert Gas Shielded Welding - 8 -
degreased
Protect yourself from excessive noise- welding can be noisy!
ocess and grinding can generate noise ensure you wear ear protection if necessary
Protect yourself and others from electric shocks- they can be fatal!
emove rings and metallic watch straps
ear protective clothing including overalls and insulating safety boots
tand or kneel on a dry surface when welding
nly use a TIG torch in good condition
Do not weld in the rain without a suitable cover
Protect yourself and others from fire – fires start easily!
Protect yourself and others from fumes – by using the correct extraction!
Welding fumes can cause lung irritation and long term lung damage
Make sure fume extractors are working and positioned correctly (ask you tutor to show you)
Welding materials must be clean and
Welding pr
R
W
S
O
QIWS/001 – Tungsten Inert Gas Shielded Welding - 9 -
Remove any flammable material from the welding area Beware of containers that may have contained flammable materials Know wh extinguishers are kept (for use onelectrical equipment) Ensure y
ere CO2 or powder fire
our tutor has explained to
are of fire exits and the
evacuation procedure
ype and use of fire extinguishers – learn the right extinguisher for the right job
you how to use the correct type of fire extinguisher
Be aw
T
Extinguisher Type (Coloured ban red bod white wrd on y with iting)
Water Foam Powder CO 2 Class of Fire
Paper, Wood, Textiles, Fabric
Flammable Liquids
Flammable Gases
Electrical Equipment
Transport, Domestic eg boats, cars, caravans, the home
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Explosions – consider what you are actually welding!
There is a great danger of explosion or fire when welding containers that have previously contained explosive or flammable substances, such as petrol or oil; flammable materials can be trapped in:
grooves seams riveted joints
Never weld old oil cans or petrol tanks unless before welding, the following action must be carried out:
Remove explosive materials by steaming out with a low pressure steam cleaner and before welding the atmosphere inside the container must be certified as safe.
Compressed gas cylinders – always treat with respect! Cylinders of compressed gas must always be treated with respect; great care should be taken in moving them around the workshop, connecting them to welding equipment and in their storage. Safety rules include: Moving cylinders
Always use an approved type of cylinder trolley to move cylinders
Never move cylinders with their regulators attached
If necessary to move by hand it should only be over short distances
Always ensure your pathway is clear before starting to move a cylinder
Never move cylinders over cables etc
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Safety signs - protect yourself and others
Prohibition signs – must be obeyed Circular signs with red surround and diagonal red line.
NO SMOKING
Mandatory signs – must be carried out Circular blue signs
WEAR EYE PROTECTION
Warning signs – warns of hazard or danger Yellow triangular signs with black symbol and surround
DANGER HIGHLY FLAMMABLE
Information signs – to advise Green square signs
FIRE EXIT
All taken from http://www.onlinesign.com/build_sign.php?pic=58
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What equipment do you use for TIG welding?
Ask your tutor to show you and identify each equipment
component listed below.
(PPE) Personal protective
equipment Gloves
Welding helmet Boots
Overalls
TIG power source (power source)
Conduit/harness Welding torch Return lead Gas cylinder Regulators Flow meter
Consumables Tungsten electrodes
Filler wire Shielding gas
Tools and equipment Wire brush
Work bench Welding booth and
curtains Extraction
The TIG Power Source Current control: The current can be controlled by using a dial on the welding machine. The current will vary according to the thickness of the metal.
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TIG welding set (power source) TIG power sources mostly use a transformer rectifier. This type of power source creates an AC welding current and rectifies it to a DC welding current. The DC welding current is used for steel and stainless steel and the A.C. current for aluminum. The power source has a control so you can choose which type of current you need. (A rectifier is an electrical device which converts alternating current (AC) to direct current (DC) this process is known as rectification.) Once the TIG welding machine has been set up correctly, it will provide the correct power for the TIG welding process.
Electrical connections There are two cables connected to and from the welding machine:
the welding lead (harness or conduit) the welding return attached to the return clamp
The welding machine will have its own separate electrical earth lead. TIG welding torch (ask your tutor to show you these components) The welding torch can be air or water cooled and is made up of the:
collet ,collet holder and backcap (to insulate and grip the tungsten electrode)
gas lense (which focuses the gas glow) ceramic shroud (guides the shielding gases onto the
welding area) tungsten electrode nozzle (made out of heat resistant material)
QIWS/001 – Tungsten Inert Gas Shielded Welding - 14 -
17.html
Ignition switch/foot control The current to the welding torch can be controlled by the ignition switch on the torch body or from a remote foot control
Shielding Gas The shielding gases used for TIG welding are pure argon or helium/argon mixture, which are supplied in cylinders or piped directly into the workshop. The pressure regulator on the cylinder allows the operator to adjust the gas flow rate for the type of welding. There is a flow meter on the cylinder to allow find adjustment and show the flow rate.
Tungsten Electrode The tungsten electrode is made from tungsten or a tungsten alloy, tungsten has the highest melting temperature among pure metals, at 3,422 °C (6,192 °F). As a result, the electrode is not consumed during welding, though some erosion can occur.
Tungsten electrodes need to be ground to a specific point shape to suit the current being used. They can be ground freehand or using a special grinding machine. (Ask your tutor to show you how they are sharpened)
Filler wire The welder may add filler wire into the molten pool as welding progresses. The filler wire will be made of the same metal as the materials being welded. It is normally supplied in large sealed plastic tubes. Steel wire will be coated in copper to protect from corrosion.
Further information on TIG welding equipment can be found at http://www.twi.co.uk/content/jk
QIWS/001 – Tungsten Inert Gas Shielded Welding - 15 -
Starting to Weld
Striking the arc:
set the power source up in terms of current type and level relevant to material thickness
hold the tungsten approx 3-4mm above the surface of the work press the foot pedal (if using foot control) or the switch on the torch the high frequency will automatically start the arc .
Making a good weld relies on:
using the correct diameter and type of filler wire using the correct shielding gas type, flow and pressure rate using the correct current type (AC or DC) keeping the arc length consistent consistent speed and angle of tungsten tip movement along the plate feeding the filler wire in a regular and uniform way making smooth joins when stop and start mid way through a weld
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Possible defects with welds
Defect name Possible reason for defect
Poor weld appearance Bad technique or machine not set up correctly – check with your tutor
Tungsten inclusion Poor technique allowing the tungsten to touch down
Undercut Poor technique - ask your tutor to show you
Lack of fusion/penetration Poor technique or settings too low
Porous weld Lack of shielding gas or dirty plate - check flow meter and material cleanliness
Weld too wide or too narrow
Poor technique, moving too fast or too slow- ask your tutor to show you
Parts of a fillet weld
The different areas of a fillet weld are named to allow them to be identified and measured against any weld standards. The leg length gives you the size of the fillet, so if the leg length measured 5mm you would have a 5mm fillet weld.
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Section 4 : Welding procedure specifications and assessment sheets
Welding Procedure Specification:
Learning Outcome 1 – Beads on Plate in the flat (PA) position (TIG)
Joint type: Beads on plate
Welding position: PA
Parent Material Type: Low carbon steel (LCS)
Dimension of test piece:
Thickness: 1.0 -3mm.
Length: 150mm minimum.
Width: 50mm minimum
Weld preparation Plates should be degreased and wire brushed prior to welding
Run sequence and completed weld
Method of Preparation and Cleaning: Degrease / mechanical dressing / wire brush.
Run No. Tungsten Electrode dia
Amperage (range)
Arc Voltage (range)
Polarity Gas Flow Rate:
1 2.4mm 80 -120 12-15 dc -ve 5 – 8 litres/min
Other Information: Two parallel weld beads to be completed for full length of plate There is no requirement to complete a stop start on this w but if one is attempted it will be assessed along with
Remo g and sp ean w br rind fi ld surfacdamage.
eldthe weld.
ve any sla atter and cl eld with wire ush, do not g nished we e, avoid surface
Welding Consumables:
Filler material: Suitable carbon steel solid wire Visual ex
Composition: In accordance with BS EN440: 1995
Shielding gas: Argon
Non destructive testing:
amination only – details on assessment sheet
QIWS/001 – Tungsten Inert Gas Shielded Welding - 18 -
Learning Outcome 1 – Beads on Plate in the flat (PA) position (TIG)
All essen rabletial items and 2 from 3 desi must pass assessment
Learner name: Date of completion:
Decision Pass Fail Assessor Comments 1. Uniformity The weld is uniform and width does not vary more than 4mm along length (desirable)
The weld toes blend without cold lapping (essential)
The weld reinforcement is of even height along weld length (essential) The weld is free from cracking (essential)
No single cavity or inclusion is more than 3mm in any direction or any group more than 3m in total (essential)
2. Undercut Undercutting (intermittent) does not exceed 1.5mm depth (desirable) Undercutting does not exceed 50% of total weld length(desirable) No single undercutting exceeds 25mm (desirable)
Assessor General Comment
Assessor Signature
Learner Signature
Pass Mark (delete as appropriate) Task Pass/Fail
Date of re-assessment (if applicable)
QIWS/001 – Tungsten Inert Gas Shielded Welding - 19 -
edure Specificati n:
fille ontal/vertic l (PB) position (TIG)
Welding Proc o
Learning Outcome 2 – Lap t in the horiz a
Joint type: Lap fillet
Welding position: PB
Parent Material Type: Low carbon steel (LCS)
Dimension of test piece:
Thickness: 1.0 -3mm.
Length: 150mm minimum.
Width: 50mm minimum
Weld preparation
Run sequence and completed weld
Method of Preparation and Cleaning: Degrease / mechanical dressing / wire brush.
Run No. Tungsten Electrode dia
Amperage (range)
Arc Voltage (range)
Polarity Gas Flow Rate:
1 2.4mm 80 -120 12-15 dc -ve 5 – 8 litres/min
Other Information: Ensure plates are clamped and tack welded prior to welding There is no requirement to complete a stop start on this weld but if one is attempted it will be assessed along with the weld.
Remove any slag and spatter and clean weld with wire brush, do not grind finished weld surface, avoid surface damage. Welding Consumables:
Filler material: Suitable carbon steel solid wire
Composition: In accordance with BS EN440: 1995
Shielding gas: Argon
Non destructive testing: Visual examination only – details on assessment sheet
QIWS/001 – Tungsten Inert Gas Shielded Welding - 20 -
Learning Outcome 2 – Lap fillet in horizontal/vertical (PB) position (TIG)
A
ll essential items and 3 from 5 desirable must pass assessment
L n: earner name: Date of completio
Decision Pass Fail Assessor Comments 1. Alignment Linear misalignment should not exceed +/- 3mm of c )
entre line (desirable
2. Uniformity The weld is uniform and width does not vary more than +/- 3mm along length (desirable)
Leg length must not exceed metal thickness + 2mm (essential)
The weld toes blend without cold lapping (essential)
The weld reinforcement is of even height along weld length (essential)
The weld i
s free from cracking (essential)
No single cavity or inclu an 3a or any group an 3m in(
sion is more th mm in ny direction more th total essential)
3. Undercut Udepth (desirable)
ndercutting (intermittent) does not exceed 1.5mm
Ul rable)
ndercutting does not exceed 50% of total weld ength(desi
N
o single undercutting exceeds 25mm (desirable)
Assessor General Comment
A ssessor Signature
Learner Signature
Pass Mark (delete as appropriate) Task Pass/Fail
Date of re-assessment (if applicable)
QIWS/001 – Tungsten Inert Gas Shielded Welding - 21 -
Learning Outcome 3 – Tee fillet in the flat (PA) position (TIG)
Welding Procedure Specification:
Joint type: Tee fillet Dimension of test piece:
Welding position: PA
Parent Material Type: Low carbon steel (LCS)
Thick
: 150mm minimum.
idt m
ness: 1.0 -3mm.
Length
W h: 50m minimum
Weld preparation
Run sequence and completed weld
450
Method of Preparation and Cleaning: Degrease / mech ical dressing / e brush. an wir
Run No. Tungsten Amperage )
Arc Voltage (range)
Polarity Gas Flow Rate: Electrode dia (range
1 2.4mm 80 -120 12-15 dc -ve 5 – 8 litres/min
Other Informa
tion:
welding
on th weld b f one i attempted it will be assessed along with
re rush, do not grind finished weld surface, avoid surface damage.
Ensure plates are clamped and tack welded prior to There is no requirement to complete a stop startthe weld.
is ut i s
Remove any slag and spatter and clean weld with wi b
Welding Consumables:
aterial: Suitable carbon steel solid wire
In accordance with BS EN440: 1995
Non destructive testing: Visual examination only – details on assessment sheet
Filler m
Composition:
Shielding gas: Argon
QIWS/001 – Tungsten Inert Gas Shielded Welding - 22 -
L e flat (PA) position (TIG)
A
earning Outcome 3 – Tee fillet in th
ll essential items and 3 from 6 desirable must pass assessment
L n: earner name: Date of completio
Decision Pass Fail Assessor Comments 1. Alignment Linear misalignment should not exceed +/- 3mm of c )
entre line (desirable
Angular alignment is within +/_ 50 from 900
(desirable)
2. Uniformity The weld is uniform and width does not vary more than +/- 3mm along length (desirable)
Leg length must not exceed metal thickness + 2mm (essential)
The weld toes blend without cold lapping (essential)
The weld rel
inforcement is of even height along weld ength (essential)
The w rom crac al)
eld is free f king (essenti
N ity or inclusio e than 3a roup more than 3m in total (esse
o single cav n is mor mm in ny direction or any g
ntial) 3. Undercut Undercutting (intermittent) does not exceed 1.5mm d
epth (desirable)
U does not exceed 50% of total weld l
ndercuttingength(desirable) N ndercutting exceeds 25mm (desirable)
o single u
Assessor General Comment
Assessor Signature
L earner Signature
Pass Mark (delete as appropriate) Task Pass/Fail
Date of re-assessment (if applicable)
QIWS/001 – Tungsten Inert Gas Shielded Welding - 23 -
Welding Procedure Specification:
Learning Outcome 4 – Tee fillet in the horizontal/vertical (PB) position (TIG)
Joint type: Tee fillet
PB
ype: Low carbon steel (LCS)
n of test piece:
ckn 1.0
Lengt 150mm minimum.
Width 50mm minimum
Welding position:
Parent Material T
Dimensio
Thi ess: -3mm.
h:
:
Weld preparation
Run sequence a d completed weld
n
Method of Preparation and Cleaning: Degrease / mech ical dre sing / wire brush. an s
Run No. Tungsten Amperage
Arc Voltage (range)
Polarity Gas Flow Rate: Electrode dia (range)
1 2.4mm 80 -120 12-15 dc -ve 5 – 8 litres/min
Ot er Inforh mat
ion:
el ing
on thi ld bu if one is will be assessed along with
ire brush, do ot grind shed weld surface, avoid surface damage.
Ensure plates are clamped and tack welded prior to w
d
There is no requirement to complete a stop start the weld.
s we t attempted it
Remove any slag and spatter and clean weld with w n fini
Welding Consumables:
iller material: Suitable carbon steel solid wire
dance with BS EN440: 95
Non destructive testing: Visual examination only – details on assessment sheet
F
Composition: In accor 19
Shielding gas: Argon
QIWS/001 – Tungsten Inert Gas Shielded Welding - 24 -
orizontal/vertical (PB) position (TIG)
Learning Outcome 4 – Tee fillet in h
All essential items and 3 from 6 desirable must pass assessment
Learner name: Date of completion:
Decision Pa mments ss Fail Assessor Co1. Alignment Linear misalignment should not exceed +/- 3mm of
le)
centre line (desirabAngular alignment is within +/_ 50 from 900
(desirable)
2. Uniformity The weld is uniform and width does not vary more than +/- 3mm along length (desirable)
Leg length must not exceed metal thickness + 2mm (essential)
The weld toes blend without cold lapping (essential)
The weld reinforcement is of even height along weld length (essential)
The w from cra ntial)
eld is free cking (esse
No single cavity or inclusi re than 3group more than 3m in total
on is mo mm in any direction or any
ntial) (esse3. Undercut Undercutting (intermittent) does not exceed 1.5mm depth (desirable) Undercutting does not exceed 50% of total weld length(desirable) No single undercutting exceeds 25mm (desirable)
Assessor General Comment
Assessor Signature
Learner Signature
Pass Mark (delete as appropriate) Task Pass/Fail
Date of re-assessment (if applicable)
QIWS/001 – Tungsten Inert Gas Shielded Welding - 25 -
Welding Procedure Specification:
Learning Outcome 5 – Corner weld in the flat (PA) position (TIG)
Joint type: Outside corner
elding position: PA
t Material Type: Low carbon steel (LCS)
Dimen
ss: 1.0
gt mm
Width 50mm minimum
W
Paren
sion of test piece:
Thickne -3mm.
Len h: 150 minimum.
:
Weld preparation
Run sequence and completed weld
Method of Preparation and Cleaning: Degrease / mech ical dre sing / wire brush. an s
Run No. Tungsten Electrode dia
Amperage (range)
Arc Vol age (range)
Polarity Gas Flow Rate: t
1 2.4mm 80 -120 12-15 dc -ve 5 – 8 litres/min
Other Information:
lamped and tack welded prior to welding
hi ld bu if one is will be assessed along with
Remove any slag and spatter and clean weld with wire brush, do not grind shed weld surface, avoid surface
Ensure plates are c There is no requirement to complete a stop start on t s we t attempted it the weld.
finidamage. Welding Consumables:
iller material: Suitable carbon steel solid wire
Composition: In accordance with BS EN440: 1995
Non destructive testing: Visual examination only – details on assessment sheet
F
Shielding gas: Argon
QIWS/001 – Tungsten Inert Gas Shielded Welding - 26 -
in the flat (PA) position (TIG)
Learning Outcome 5 – Corner weld
All essential items and 4 from 7 desirable must pass assessment
Learner name: Date of completion:
Decision Pa mments ss Fail Assessor Co1. Alignment Angular alignment is within +/_ 50 from 900 (desirable) 2. Uniformity The weld is of uniform width of face (desirable)
The weld ripples are consistent and without excessive undulation (essential)
The weld toes blend without cold lapping (essential)
The weld profile is rounded (essential)
The weld is free from cracking (essential)
No si or inclu e thanany d r any gr 3m
ngle cavityirection o
sion is moroup more than
3mm in in total
(essential)
3. Undercut Undercutting (intermittent) does not exceed 1.5mm
depth (desirable)
Undercutting does not exceed 50% of total weld length(desirable)
No single undercutting exceeds 25mm (desirable)
Assessor General Comment
Assessor Signature
Learner Signature
Pass Mark (delete as appropriate) Task Pass/Fail
Date of re-assessment (if applicable)
QIWS/001 – Tungsten Inert Gas Shielded Welding - 27 -
Section 5 : Knowledge questions TIG Welding
1. Complete the diagram showing the main hazards of TIG welding.
. List the main items of PPE and clothing to be worn during TIG welding.
2
Continued on next page
High reque cy
cF n
Ar
Hazards
QIWS/001 – Tungsten Inert Gas Shielded Welding - 28 -
3. Identify the type of weld in the diagram below.
Weld type is:……………………………………. Position is:……………………………………….
4. What is the purpose of the arc in TIG welding?
5. What is the main purpose of the active gas shield around the tungsten tip?
6. What are the consumables used in TIG welding?
Continued on next page
QIWS/001 – Tungsten Inert Gas Shielded Welding - 29 -
. What are the main items of equipment used FOR TIG welding? Complete the diagram below.
. List the main defects found in TIG welds?
9. Which types of electrical current can be used for TIG welding?
0. Why is it important to erect screens around the welding area?
7
8
Ask your tutor to
below.
show you and identify each equipment
component listed
(PPE)
TIG power source
Consumables
Tools and equipment
1
QIWS/001 – Tungsten Inert Gas Shielded Welding - 30 -
Section 5 : Knowledge questions - solutions
1. List the main hazards of TIG welding.
) TIG welding gloves ) boots welding helmet
. Identify the type of weld in the diagram below.
orner weld in the PA flat position
Continued on next page
High Frequency Arc
Electric Shock
Compressed Gas Cylinders
. List the main items of PPE and clothing to be worn during TIG welding. 2
abc)d) overalls
3 c
Hot metal And
Burns
Fire and Explosion
Welding d Fumes an
Noise
Hazards
Arc
Radiation
QIWS/001 – Tungsten Inert Gas Shielded Welding - 31 -
To produce heat to melt the filler rod and parent metal
gas shield around the tungsten tip?
To protect the weld from contamination
6. What are the consumables used in TIG welding?
filler rods Shielding gas
7. What are the main items of equipment used for TIG Welding? Complete the diagram below.
ontinued on next page
4. What is the purpose of the arc in TIG welding?
5. What is the main purpose of the active
Ask your tutor to show you and identify each equipment
component listed below.
(PPE) Personal protective
Welding helmet
veralls
TIG power source (power source)
return lead
Consumables Tungsten electrodes
gas cylinder regulators flow meter
Tools and equipment Wire brush
Work bench Welding booth and
curtains Extraction
equipment Gloves
Boots O
conduit/harness welding torch
Filler wire Shielding gas:
C
QIWS/001 – Tungsten Inert Gas Shielded Welding - 32 -
Poor weld appearance
Undercut Porous weld
r TIG welding?
0. Why is it important to erect screens around the welding area?
eople from Arc radiation
8. List the main defects found in welds?
Tungsten inclusion
Weld too wide or too narrow
9. Which types of electrical current can be used fo
AC and DC current
1 To protect other p
QIWS/001 – Tungsten Inert Gas Shielded Welding - 33 -
pletion – Unit 001 TIG
Section 7 : Declaration of com
Learner name: Date of completion:
Assessor name: Centre Name:
Task details Date completed
Assessor signature
1. Produce beads on plate in the PA flat position
2. Produce a lap fillet weld in the PB
horizontal/vertical position
3. Produce a tee fillet weld in the PA flat position
4. Produce a tee fillet weld in the PB horizontal/vertical position
5. Produce a corner weld in the PA flat position
6. Know the Process and Health & Safety requirements of TIG welding – knowledge test
Assessor General Comment
Assessor Signature
Learner Signature
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