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Sharp Point Indicates Penetration This first pass is criti-

cal, and it must be mas-


tered before the welding
of the pipe joint may be
considered satisfactory.
Control of penetration
is the most important
factor in successful root
pass welding. Such con-
trol can be obtained
only by repeated prac-
tice. Satisfactory ser-
vice of the pipe joint can
Fig. 20-19 Contour of the weld pool when penetration is be obtained only if the
obtained. root pass is solid. See
Fig. 209, page 634, for
Notch Indicates Incomplete Penetration
the proper appearance
of the back side of the
root weld and Fig.2021
for the appearance of the
face of the weld.
Improper termina-
tion and restart of the
weld beads increase the
probability of defects in Fig. 20-21 Face contour of a
the weld. Figures20-22 satisfactory root pass in stainless-
and 20-23 show the steel pipe. Crane Co.
proper termination of
the weld bead. The weld bead is overlapped approxi-
mately three times the width of the bead, and the size
Fig. 20-20 Contour of the weld pool when penetration is not of the weld pool is reduced by rapidly increasing the
obtained. weld travel speed. The weld pool is directed off the side
of the joint so that it may be terminated in a section that
is relatively heavy in wall thickness. This decreases the
Fig.20-20. The presence of the notch in the weld pool in- chill on the weld pool and prevents cracks in the weld
dicates the absence of penetration on the inside of the pipe. crater. In starting the weld after the interruption, begin
There are other signs that indicate penetration and con-
tour of the weld bead on the inside of the pipe. When the Proper Termination of Weld Bead
pool is first formed, the surface across the center is raised
(convex). When the point formation is obtained on the
lead edge of the weld pool, observe the convex surface
carefully. Soon after the point formation is obtained, the
convex surface of the pool suddenly becomes flat. At this
instant, advance the electrode along the line of weld until
this surface again appears to be convex. If the pool is al-
lowed to pass through the flat stage to the concave stage,
too much penetration will result.
Excessive penetration can be overcome by adding more
filler rod to the pool. Slant the torch toward the filler rod
so that more rod is melted and increase the speed of weld-
ing. This directs more heat to the rod and less to the pipe Fig. 20-22 Proper ending of the weld bead prevents crater
surface to reduce the amount of heat in the weld pool. cracks.

638Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)


the pool inch or more enough finesse, the cup will slip out of the bevel or forward
back from the end of the and control is lost. With the gas cup resting directly in the
previous bead to ensure groove, a much more relaxed feel can be developed.
good fusion of the two The tungsten should be extended approximately inch
beads, Fig.20-24. beyond the gas cup. This should provide a torch angle that
With GTAW and es- is 45 to 60, which is correct for the walking the cup
pecially the root pass on method. Note this is much different than the freehand
a pipe joint the idea is to method, which has the electrode pointed at the center of
use finesse, not muscle. the pipe.
Get into the most relaxed
and comfortable position Filler Passes Filler passes are used to fill the pipe joint
possible. Welders de- to within approximately 116 inch of the top surface of the
velop their own personal pipe. Heavier passes can be used for the filler pass when
techniques. It is generally making a rolled weld than when welding in a fixed posi-
more difficult to main- tion since the weld pool does not have a tendency to sag
tain control of the arc out of the joint due to gravity.
length and the weld pool Follow the same procedure as for the root pass. Either
using the freehand stringer beads or weave beads can be used for the filler
Fig. 20-23 Face of a root pass method. The walking passes in carbon and low alloy steel pipe welded in the
that shows proper termination
the cup method allows rolled 1G or fixed horizontal 5G position.
where the bevels meet. This is a
V-groove butt joint in stainless- for more control on the The stringer bead technique should be used for welding
steel pipe. root pass. aluminum and stainless-steel pipe in any position when the
wall thickness is more than inch. Stringer beads should
also be used for carbon and low alloy steel welded with the
pipe in the vertical fixed 2G position.
For video of GTAW cup walking technique, please visit Each stringer bead should be made completely around
www.mhhe.com/welding. the pipe before starting the next bead. Stringer beads on
stainless steel should be kept small since the weld bead
solidifies quickly. Fast freezing prevents the precipitation
of carbides in these steels and reduces the tendency for
In walking the cup the gas cup size is very important.
hot-short cracking.
The cup should fit into the groove and not want to slip out.
Care must be taken so that succeeding welding opera-
Removing any sharp edges on the gas cup that will be con-
tions do not interfere with, or destroy, the inside surface of
tacting the pipe groove face and at the same time putting a
the root pass weld. For the root pass, the torch is directed to-
radius on the gas cup will keep it in the groove. Apply light
ward the center line of the pipe. When making filler passes
pressure to easily slide or step the cup forward in a uniform
on pipe, however, you must incline the torch at an angle of
side-to-side motion. If you apply too much muscle and not
approximately 45 to a point tangent to the surface of the
pipe as shown in Fig. 20-25.
Clean the root pass and each succeeding pass carefully
End of Weld Bead with a stainless-steel wire brush.
The filler layer may be made with a single weave bead
or with two stringer beads. If a weave bead is used, weld
/
14
with a 332-inch filler rod. Clean the first pass thoroughly
in order to remove surface oxides. The electrode should
be held as instructed above. Move the arc from side to
side, and add filler rod as rapidly as it melts off. Direct the
arc on the side walls of the pipe to avoid burning through
the first pass, Fig. 20-26A. If you have difficulty with the
weave bead technique, run stringer beads. Make the welds
Pick Up Weld Bead along the sides of the pipe with 116-inch filler rod and over-
lap at the center, Fig. 20-26B. Advance the torch with a
Fig. 20-24 Restarting a weld bead. slight oscillating motion in the direction of welding, and

Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20639
Electrode Center Line Cover Passes Smooth, uni-
form finish passes can
be made only if the filler
Filler Rod passes are smooth and
free of undercut at the
edges, and the pipe joint
is filled to a uniform level.
Care spent in making
smooth filler passes will
result in finished welds of
excellent appearance as
well as quality.
Follow the proce-
dure described for the
Electrode Positioning for Filler Rod Additions. root and filler passes. Fig. 20-27 Face appearance of
Stringer beads or weave a filler pass in a V-groove butt joint
Fig. 20-25 Proper relation of the electrode to the pipe for addi-
tion of filler rod on the filler and cover passes. beads may be used for in stainless-steel pipe.
carbon and low alloy
steel pipe in the rolled
Second pass roll weld
or fixed horizontal 5G
play arc on these areas. position. Stringer beads
must be used for carbon
and low alloy steel pipe
in the vertical fixed po-
sition, and for stainless
or aluminum pipe in any
position.
Finished cover passes
should be about 332 inch
Avoid overheating this area. Weld will wider than the beveled
plunge through if it gets too hot.
edges on each side of
A Fig. 20-28 Face appearance of
the joint, and the overlap a cover pass in stainless-steel pipe.
should be spaced evenly
on each side of the joint. The face of the weld should be
slightly convex, and the reinforcement should be about
1
16 inch above the surface of the pipe. Weld edges should
be straight and without any undercutting. Figure 20-28
shows the proper appearance of the cover pass. Also see
Fig. 20-47, page 646.
When you are able to make welds that have good pen-
etration through to the back side, good appearance, and
Torch Motion are satisfactory to your instructor, make up a test weld
Try 2 stringer beads over first pass using 1/16 rod. and remove the usual test coupons for root- and face-
Do not weave. bend testing.
B

Fig. 20-26 Filler pass welding techniques. Horizontal Fixed Position


with 180 Rotation
add filler rod as rapidly as possible. Making stringer beads This weld is another version of Job 20-J2, but welding
reduces the problem of burning through due to excessive is done on the top side only. The pipe is in the hori-
heat in the center of the first pass. Figure 20-27 shows the zontal 5G position and the weld is vertical. The weld is
proper appearance of stringer beads. completed in two halves. Start the weld slightly below

640Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)


Fixed Position Fixed PositionHorizontal Weld
Weld Top Half Only

Overlap
4
3

Start
First Pass Second
Pass
Finish
Start Weld Here
Place one weave or two stringers over the first pass
before turning over the pipe. 1
2

Overlap
Weld on quarters with good overlap of first pass
to ensure good penetration bead.

Fig. 20-30 Welding procedure for the root pass in pipe in the
Be Careful to Tie in vertical fixed (2) position.
Penetration Bead
Start First Pass with First Half
of Second Side
First Pass
Here Second Stringer
Welded Area

Fig. 20-29 Welding the top side of the pipe in the horizontal
fixed (5) position.

the center line of the pipe as shown in Fig. 20-29, and


weld toward the top and beyond top center. The other
side of the pipe is started in the same way and proceeds
to the top. The second weld overlaps the first by about
three widths of the weld. The filler and cover passes are
welded as previously described with either the weave or
stringer bead technique.
When the cover passes are completed, rotate the pipe Watch for Point
First Stringer
180 and weld the second half as described above. Be sure First Pass Cover Pass
that the welds in the first pass overlap at both their start
and finish to avoid incomplete fusion. Fig. 20-31 Welding procedure for the first pass and the cover
pass on pipe in the vertical fixed (2) position.
Vertical Fixed Position:
Jobs 20-J8, J9, J10, and J11

Root Pass The pipe is in the vertical 2G position, and the same as for rolled pipe, special techniques are re-
joint is in the horizontal position. The first pass is made in quired to compensate for the sagging of the pool due
four quarters. You should change position as each quarter to gravity.
is completed to make sure that you can observe the lead- Position your torch as shown in Figs. 20-32 and 20-33
ing edge of the weld as it progresses. The first pass should (p. 642). The weld pool is formed on the upper pipe bevel
overlap at each start and at the finish, Fig. 20-30. The first and is kept slightly above the center line of the joint. Move
pass and the cover passes should be made as shown in the torch in small circles. Proceed from the top of the
Fig.20-31. pool, around the pool to the bottom, and then up the other
Although the shape of the pool and the flow of side to the top. Do not let the arc dwell too long on the
the molten pool for the vertical fixed position are the bottom, but let it favor the top of the weld. This circular

Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20641
Fig. 20-32 Torch position for welding with pipe axis in the vertical
orientation. The weld is being made in the horizontal (2) position. Fig. 20-34 Welding the root pass without the use of a filler rod.
Joint preparation is U-groove, and the pipe is being rolled with its
axis in the horizontal direction. The weld is being made in the flat (1)
position. Crane Co.

electrode should be pointed


straight in or slightly upward 3 6
for this pass.
The rest of the passes,
1 5
including the cover passes,

should overlap the preceding
4
passes. The torch should be 2
pointed up or down, depend-
ing on the pass sequence. Keep
the welds small and make sure Welding Sequence
that you are securing good
fusion with the preceding
welds and the pipe surfaces.
The pool must be kept fluid,
Fig. 20-33 A properly cleaned pipe inside and out being tacked and the forward edge should
together. The pipe axis in the vertical orientation. The weld will be
made in the horizontal (2) position. Filler metal is being used on this
flow without being forced by
V groove weld on a butt joint. Location: Northeast Wisconsin Technical the filler rod or torch. Add the 3 5 6
College McGraw-Hill Education/Mark A. Dierker, photographer filler rod sparingly so that the
pool does not get too large and
motion ensures fusion of the bottom of the joint with the so that cold rod is not depos-
filler rod, and yet it does not undercut the upper side of ited on the bead or pipe sur- 2 4

the weld bead. faces. Be sure to clean each


When the pipe is prepared with a U-groove, consum- pass thoroughly before apply-
able insert, or rolled edge, the root pass may be welded ing the next pass.
without filler rod, Fig. 20-34. When you are able to make
welds that show good penetra-
Filler and Cover Passes The filler and cover passes tion through to the back side,
should be made as shown in Fig. 20-35. The first filler have good appearance, and are
Fig. 20-35 Stringer
pass should be a stringer bead made with 116 - or 332 inch satisfactory to your instructor,
beads on pipe with axis in
filler rod and a slight oscillating technique. This pass make up a test weld and remove the vertical orientation in the
should cover all or two-thirds of the root pass, de- the usual test coupons for root- horizontal (2) position with
pending on the thickness of pipe wall. The tungsten and face-bend testing. weld sequence (top).

642Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)


Fig. 20-36 Welding of carbon steel with the
pipe axis in the horizontal fixed orientation. The
weld is started at the bottom, and travel is up. This
is a (5) position weld. Filler metal is being used on
this V groove weld on a butt joint. Location: North-
east Wisconsin Technical College McGraw-Hill Edu-
cation/Mark A. Dierker, photographer

Fig. 20-37 Welding aluminum with the pipe axis in the horizontal fixed orienta-
tion. Note the tight situation for the welder to make this position 5 weld. The travel
direction is up. Sypris Technologies, Inc. -Tube Turns Division

Horizontal Fixed
Position (Bell
Hole Weld): Jobs
20-J12J17
The pipe is in the hori-
zontal position, and the
weld is vertical, Figs.
20-36 and 20-37.
When making a pipe
weld in the horizontal
fixed 5G position, you
will practice all the
welding positions: flat,
vertical, and overhead.
The weld will be made
at a constantly chang-
ing angle. The ability
to make welds of this
nature that pass the
regular tests marks the
welder as a craftsperson. Fig. 20-38 Welding aluminum Fig. 20-39 Welding aluminum pipe in the side portion of a bell
pipe in the bottom portion of a bell
Figures 20-38 through hole. The welding position changes from the overhead to the verti-
hole. This is an overhead weld- cal position. This is a position 5 weld. Kaiser Aluminum
20-40 show the change ing, travel up and is a (5) position
of position from bottom weld. Kaiser Aluminum
to top.
Root Pass The same general welding technique fol- however, to get the proper penetration without getting
lowed previously for the welding of rolled pipe may a concave root surface when you are welding overhead.
also apply to welding in the horizontal fixed 5G po- Your response to the demands of the pool must be im-
sition. You must control the weld pool more closely, mediate. You may find it helpful to weld with lower

Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20643
Fourth Finish
Section
Second
Section

Third Section Cover Pass


First Section
Start

Run two stringers for cover pass.


Overlap all starts and stops.
Fig. 20-40 Welding aluminum pipe in the top portion of a bell
hole. The welding position changes from the vertical to the flat posi- Fig. 20-42 Welding procedure for filler and cover pass on pipe
tion. This is a position 5 weld. Kaiser Aluminum in the bell-hole (5G) position.

current values in order to secure a smaller weld pool. The Filler and/or Cover Passes The filler and/or cover
Keep the face of the weld as flat as possible and free passes should be made as shown in Fig. 20-42. These
of undercut. passes may be either stringer or weave beads. The first
The weld bead should be started past bottom cen- filler pass must be applied with great care because the
ter. The welding should progress downhill across the root pass made with the gas tungsten arc process is likely
bottom of the pipe and then uphill to the top of the to be thin, and the danger of burning through is always
pipe past the 12 oclock present. Keep the filler rod in contact with the bottom of
Fixed Position point, Fig. 20-41. If the the joint, and do not remove it from the weld pool. This
or
welding is interrupted in limits the penetration into the root pass and helps prevent
Bell-Hole Weld
order to change position burn-through. Do not let the arc dwell in the center of the
Overlap as you travel around the bead. Keep it on one side when making stringer beads, or
pipe, be careful to over- move it quickly from one side of the joint to the other for
lap the bead at each start weave beads. Make sure that the pool blends into the sides
after removing the sur- of the joint and that it is fused to the bead underneath.
face oxides. Be sure to clean each pass thoroughly before applying the
The second half of the next pass.
first pass should overlap When you are able to make welds that show good pen-
the starting point of the etration through to the back side, have good appearance,
first half of the weld. The and are satisfactory to your instructor, make up a test weld
welding should then pro- and remove the usual test coupons for root- and face-bend
Start
Weld ceed to the top and overlap testing.
Overlap Here the previous weld at the top,
Overlap Second Half of First Pass Fig. 20-41. There will be a
tendency for the middle of Inspection and Testing
Fig. 20-41 Welding proce- the first pass to be concave When completing the remaining jobs assigned from
dure for root pass on pipe in
bell-hole position. This is cor- and wide. Avoid weld- the Job Outline, inspect each pass carefully for weld
rectly called the 5G position for ing with too little current. defects. Compare root passes with the specifications
groove welds. Travel as fast as possible. given in Fig. 20-7 and the actual appearance shown

644Chapter 20Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe)


Fig. 20-43 Face appearance of the cover pass in a butt Fig. 20-44 Face appearance of the cover pass in a butt joint in
joint in stainless-steel pipe welded with the TIG process. Slight stainless-steel pipe welded with the gas tungsten arc welding pro-
reinforcement. cess. Relatively flat.

in Figs. 20-8 and 20-9, pages 633634. Also inspect


the outside surface appearance of the root pass and
compare it with Figs. 20-21, page 638, and 20-23,
page639.
Finished welds in stainless and aluminum pipe should
have the appearance shown in Figs. 20-43 through 20-48.
Look for essentially the same good weld characteristics
that you have been striving for in shielded metal arc weld-
ing practice and gas tungsten arc welding practice on
plate. Review the visual acceptance criteria covered in
Tables 4-1 through 4-3, pages 117129.
Testing to determine welder qualification for
stainless-steel pipe is usually done by welding together two
6-inch lengths of stainless-steel pipe 1inch in diameter.
One joint is welded in the horizontal fixed 5G position
and a second is welded in the vertical fixed 2G position.
The specimens are subjected to a tensile pull test. The Fig. 20-45 Surface appearance of the cover pass in a butt joint
weld reinforcement is removed. Successful specimens in aluminum pipe welded with the TIG process.
will reach a load limit of more than 75,000 p.s.i. before
breaking. Failure may take place in the weld or the pipe
wall. Branch Welds
Testing may also be done on larger diameter pipe. To After you have demonstrated that you are able to make
test your practice welds in both stainless steel and alumi- satisfactory groove welds in pipe of various materials, you
num, remove face- and root-bend specimens from the top, may wish to practice a number of branch (lateral) joints.
bottom, and sides of the pipe and subject them to bending Both 90 and 45 branches are suggested. These are similar
stress. This test is similar to the testing procedures for the to those done with the shielded metal arc process, using
shielded metal arc welding of plate and pipe and for the the stringer bead technique. Completed welds should have
gas tungsten arc welding of plate. the appearance shown in Figs. 2046 and 20-48.

Gas Tungsten Arc Welding Practice: Jobs 20-J1J17 (Pipe) Chapter 20645

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