TIG Pipe Welding Course

Lesson 1 • Tungsten Electrode Preparation

Teaches grinding, pointing, and balling techniques for various electrode types. Proper preparation directly controls arc stability and weld quality.

Lesson 2 • Equipment Identification and Setup

Identifies power sources, torches, regulators, and filler metals. Correct setup prevents equipment damage and ensures consistent arc starts.

Lesson 3 • Safety, PPE, and Hazard Control

Addresses arc radiation, fume exposure, electrical hazards, and fire prevention. Compliance with safety practices is required before any arc-on activity.

Lesson 4 • TIG Process Principles and Physics

Covers the tungsten inert gas arc process, heat transfer, and shielding gas behaviour. Establishes the theoretical base for all subsequent hands-on work.

Lesson 1 • Fit-Up, Alignment, and Tacking

Covers pipe alignment tools, hi-lo measurement, and tack weld placement. Proper fit-up prevents misalignment defects and reduces rework.

Lesson 2 • Stainless Steel and Exotic Alloys

Covers austenitic, duplex, and nickel-alloy pipe properties relevant to TIG welding. Sensitisation, hot cracking, and distortion risks are introduced here.

Lesson 3 • Joint Geometry and Groove Preparation

Teaches bevel angles, root face dimensions, and land tolerances for pipe joints. Correct geometry ensures full penetration and sound root passes.

Lesson 4 • Preheat and Interpass Temperature

Explains preheat requirements based on material chemistry and wall thickness. Controlling interpass temperature prevents cracking and maintains mechanical properties.

Lesson 1 • Filler Metal Classification Systems

Decodes classification designations for carbon steel, stainless, and nickel filler rods. Understanding the system enables correct selection from any manufacturer's catalogue.

Lesson 2 • Consumable Verification and Traceability

Teaches heat number verification, material test reports, and traceability documentation. Traceability is compulsory in pressure piping and code-governed work.

Lesson 3 • Matching Filler to Base Metal

Applies matching and over-matching principles for strength and corrosion resistance. Mismatched filler is a primary cause of service failures in pipe systems.

Lesson 1 • Pulse Settings for Pipe Welding

Covers pulse frequency, peak current, background current, and duty cycle. Pulsing reduces heat input and improves control in all-position pipe welding.

Lesson 2 • Pre-Weld Checklist and Machine Verification

Establishes a systematic pre-weld verification routine for all machine settings. Consistent checklists reduce setup errors and improve first-pass weld quality.

Lesson 3 • AC and DC Polarity Settings

Explains DCEN, DCEP, and AC polarity selection for different pipe materials. Correct polarity determines penetration profile and oxide cleaning action.

Lesson 4 • Gas Flow and Back-Purge Setup

Sets shielding and purge gas flow rates for pipe diameter and position. Inadequate purging causes oxidation and sugaring on the root side of the weld.

Lesson 1 • Root Pass Inspection and Repair

Identifies root pass defects visually and by dimensional measurement before fill passes. Early defect detection prevents costly repairs after the joint is completed.

Lesson 2 • Torch Angle and Travel Technique

Covers work angle, travel angle, and arc length for root pass deposition. Consistent torch angles prevent lack-of-fusion and undercut at the root.

Lesson 3 • Filler rod addition technique

Teaches dip frequency, rod angle, and feed rate for root pass filler addition. Controlled filler addition prevents tungsten contamination and cold lap.

Lesson 4 • Open-root joint mechanics

Explains keyhole formation, puddle control, and root bead geometry. Understanding root mechanics is the foundation for all subsequent pass techniques.

Lesson 1 • Fill pass sequencing and layering

Teaches bead placement, interpass cleaning, and layer sequencing for groove fill. Proper sequencing controls residual stress and prevents lack-of-fusion between layers.

Lesson 2 • Interpass cleaning and contamination control

Covers wire brushing, grinding, and solvent cleaning between passes. Contamination between passes causes inclusions and porosity that fail radiographic testing.

Lesson 3 • Cap pass profile and tie-in

Addresses cap bead width, crown height, and tie-in to base metal edges. Cap pass appearance and profile are primary visual acceptance criteria for pipe welds.

Lesson 4 • Hot pass deposition and purpose

Covers the hot pass role in burning out root inclusions and refining root geometry. Correct hot pass technique sets up the groove for efficient fill passes.

Lesson 1 • Visual inspection techniques and tools

Teaches systematic visual examination using gauges, mirrors, and lighting. Visual inspection is the first and most cost-effective quality gate for pipe welds.

Lesson 2 • Weld discontinuities and defect classification

Identifies porosity, cracks, undercut, overlap, and incomplete fusion by type and cause. Correct classification guides repair decisions and process corrections.

Lesson 3 • Acceptance criteria and repair procedures

Applies acceptance criteria from pressure piping standards to weld examination results. Repair procedures must restore weld integrity without introducing new defects.

Lesson 4 • Dimensional and profile measurement

Covers reinforcement height, bead width, and undercut depth measurement. Dimensional compliance is required before non-destructive testing is performed.

Lesson 1 • Procedure qualification records

Explains how PQRs are generated through test coupon welding and mechanical testing. PQRs provide the technical basis that supports every WPS used in production.

Lesson 2 • Code-governed welding compliance

Introduces pressure piping code requirements for documentation, traceability, and oversight. Compliance protects public safety and is compulsory for code-stamped piping systems.

Lesson 3 • Welder performance qualification

Covers qualification test positions, pipe diameters, and thickness ranges for TIG pipe. Passing a performance test certifies the welder for defined production variables.

Lesson 4 • Practical qualification test preparation

Prepares students for 6G TIG pipe qualification tests through structured practise. Consistent pre-test routines and mock tests build confidence and reduce errors.