Set Up a TIG Welding Station

A. Finished-Project Specification

Outcome: one GTAW station with a correctly assembled torch, prepared and uncontaminated tungsten at the specified extension, a leak-checked and flow-verified shielding-gas system, verified polarity and current controls, a sound work-clamp connection, clean staged filler rod, a completed brief test arc, and a signed GTAW setup readiness checklist. No practice beads are produced as part of this chapter's finished work.

B. Station Component Schedule

Component	Quantity	Source / Identification	Setup Condition
Torch body, back cap, collet, collet body or gas lens, cup	1 set	Matched to the approved GTAW procedure and tungsten diameter	Assembled with correct fittings, no overtightening, verified compatible and undamaged
Tungsten electrode	As required by procedure	Approved type and diameter, identified by color code or marking	Ground to the specified point, taper, or end shape on dedicated equipment, cleaned after grinding
Shielding-gas cylinder, regulator or flowmeter, hose	1 system	Gas type specified by the approved GTAW procedure	Secured upright, leak-checked, flow set to the approved starting range
Foot pedal or hand control	1	Compatible with the power source	Connected and positioned for stable operator use
Work clamp and lead	1	Inspected in Chapter 3	Attached to clean sound metal close to the test coupon
Filler rod	As required	Approved classification and diameter, identified by package label	Cleaned, free of rust, oil, paint, or bent ends, staged in a clean labeled holder
Test coupon	1	Clean identified mild-steel scrap	Reserved only for the brief authorized test arc

C. Material Takeoff

• Tungsten: the type and diameter specified by the approved GTAW procedure, in a quantity sufficient for preparation practice and the test arc.
• Filler rod: the classification and diameter specified by the approved GTAW procedure, staged in a clean labeled holder.
• Shielding gas: the gas type specified by the approved GTAW procedure, supplied from a cylinder verified against its label.
• Test coupon: one piece of clean identified mild-steel scrap, reserved only for the brief test arc in this chapter.
• Consumables: none beyond the tungsten preparation and the brief test arc; no practice beads are produced.

D. Acceptance Standards

Check	Standard
Torch assembly	Collet, collet body or gas lens, cup, tungsten, and back cap installed with correct fittings, undamaged, not overtightened
Tungsten condition	Approved type and diameter, free of contamination, splits, excessive erosion, or mixed identification; ground to the specified end shape on dedicated equipment
Tungsten extension	Set according to cup size, joint access, and the approved procedure
Gas system	Cylinder secured upright, label and fittings verified, connections leak-checked using the approved method, flow set to the approved starting range
Polarity and controls	Machine polarity verified for mild-steel GTAW; current type, start method, amperage limit, slope, and pulse set only as specified
Work clamp	Attached to clean sound base metal close to the test coupon
Filler rod	Approved classification and diameter, free of rust, oil, paint, mixed identity, or bent ends, staged in a clean labeled holder
Test arc	Stable arc, adequate gas coverage, no tungsten contamination, correct machine response, completed only under instructor authorization
Readiness record	GTAW setup readiness checklist completed and signed before further practice

E. Preparation — Procedure Review and Area Checks

1. Review the machine manual, approved GTAW procedure, base metal, tungsten, filler rod, shielding gas, polarity, current control, and starting range. Confirm every value comes from the approved procedure, not personal preference.
2. Complete hot-work, ventilation, cylinder, fire, and PPE checks. Confirm the Chapter 1 area readiness record and Chapter 2 PPE inspection remain current for this session.
3. Inspect the power source, torch lead, work lead, work clamp, foot pedal or hand control, gas hose, and cooling system. Confirm each item is undamaged and correctly routed before proceeding.

F. Torch Identification and Isolation

1. Identify torch body, back cap, collet, collet body or gas lens, cup, tungsten, and power connection. Confirm each component is present and matched to the approved procedure before assembly.
2. Turn off and isolate the machine before assembling the torch. Confirm the machine remains de-energized for the full torch-assembly sequence.

G. Tungsten Selection and Preparation

1. Select the approved tungsten type and diameter. Confirm the selection against the approved GTAW procedure's color code or marking.
2. Inspect tungsten for contamination, splits, excessive erosion, mixed identification, and wrong diameter. Set aside any tungsten that fails this inspection.
3. Prepare tungsten using the approved dedicated grinding equipment. Do not use grinding equipment shared with other materials.
4. Direct grinding marks in the required orientation for the approved procedure. Confirm the orientation matches the procedure before continuing.
5. Do not use a contaminated general-purpose grinding wheel. Stop and locate dedicated tungsten grinding equipment if none is available.
6. Control tungsten dust according to material and shop requirements. Confirm the dust-control method matches the tungsten type in use.
7. Prepare the specified point, taper, or end shape without overheating the tungsten. Inspect the ground end against the approved procedure's shape requirement.
8. Clean the tungsten after grinding. Remove grinding debris before installing the tungsten in the torch.

H. Torch Assembly

1. Install the collet, collet body or gas lens, cup, tungsten, and back cap. Confirm each component seats correctly before tightening.
2. Set tungsten extension according to cup, joint access, and procedure. Measure the extension after the back cap is installed.
3. Do not overtighten torch components. Confirm components are secure without deforming seals or threads.
4. Verify torch parts are compatible and undamaged. Inspect the assembled torch before connecting gas.

I. Shielding-Gas Connection and Leak Check

1. Secure the shielding-gas cylinder upright. Confirm the cylinder is chained or otherwise secured before connecting the regulator.
2. Verify gas label, regulator or flowmeter, hose, and fitting compatibility. Confirm the gas matches the approved GTAW procedure before connecting.
3. Connect the gas system using clean approved fittings. Do not use damaged, contaminated, or mismatched fittings.
4. Open the cylinder from a safe position. Stand to the side of the regulator gauge face while opening the valve.
5. Leak-check the system using the approved method. Never use a flame to check for gas leaks.
6. Set initial gas flow from the approved procedure. Record the flow rate on the readiness checklist.
7. Verify pre-flow and post-flow settings where adjustable. Confirm both settings match the approved procedure.

J. Polarity, Current Controls, and Work Clamp

1. Verify machine polarity for mild-steel GTAW. Confirm the polarity setting matches the approved procedure before proceeding.
2. Set current type, start method, amperage limit, slope, pulse, or other controls only as specified. Do not set a control to a value not supplied by the approved procedure.
3. Connect and position the foot pedal or hand control. Confirm stable footing or hand position before the test arc.
4. Attach the work clamp to clean sound metal. Position the clamp close to the test coupon.

K. Filler Rod Selection and Staging

1. Select the approved filler-rod classification and diameter. Confirm the selection against the approved GTAW procedure.
2. Inspect filler rod for rust, oil, paint, mixed identity, bent ends, and contamination. Set aside any rod that fails this inspection.
3. Clean filler rod using the approved method. Remove any surface contamination before staging.
4. Position filler rods in a clean labeled holder. Keep the holder within reach of the test coupon.

L. Test Arc and Setup Verification

1. Prepare a clean matching scrap coupon. Confirm the coupon is identified mild steel and free of coating or contamination.
2. Perform a gas-flow check without striking an arc. Confirm flow at the cup before energizing the arc.
3. Verify torch cooling where applicable. Confirm the cooling system is functioning before the test arc.
4. Strike a brief test arc under instructor authorization. Do not strike the test arc without the responsible person's authorization.
5. Inspect arc stability, gas coverage, tungsten condition, and machine response. Confirm the arc is stable and the tungsten remains uncontaminated after the test.
6. Stop for tungsten contamination, gas turbulence, leaks, overheating, or unstable current. Correct any failed condition before continuing.
7. Complete the GTAW setup checklist. Verify every item in Section D against the physical station.
8. Record machine, torch parts, tungsten, grind, extension, gas, polarity, controls, filler, and readiness. Confirm the record is complete before ending the session.