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20th October 2015 TIG Welding

Russell Meredith of Northrop Aircraft perfected the process in 1941. Meredith named the process Heliarc
because it used a tungsten electrode arc and helium as a shielding gas, but it is often referred to as tungsten
inert gas welding (TIG). The American Welding Society's official term is gas tungsten arc welding (GTAW)

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Precision TIG Welded Component

Tungsten inert gas (TIG) welding became an overnight success in the 1940s for joining magnesium and
aluminium. Using an inert gas shield instead of a slag to protect the weldpool, the process was a highly
attractive replacement for gas and manual metal are welding. TIG has played a major role in the acceptance of

aluminium for high quality welding and structural applications. The process may employ direct current with
positive or negative electrode or alternating current. In general, ac is preferred for welding aluminum and
magnesium. Direct current electrode negative is preferred for welding most other materials and for automatic
welding of thick aluminum.

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TIG Welded Workpiece

Thin magnesium sometimes is welded with direct current electrode positive. When ac is used with argon shielding, an arc

cleaning action is produced at the joint surfaces on aluminum and magnesium. This cleaning action removes oxides and is
particularly beneficial in reducing weld porosity when welding aluminum. When using dc, helium may be used as the
shielding gas to produce deeper penetration. However, stringent pre cleaning of aluminum and magnesium parts is required

with helium shielding. Argon and helium mixtures for gas shielding can provide some of the benefits of both gases.

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Automatic TIG welding

Regardless of polarity, a constant current (essentially vertical volt-ampere characteristic) welding power source
is required. In addition, a high-frequency oscillator is generally incorporated in power sources designed for
GTAW. High-frequency can be employed with dc to initiate the arc instead of touch starting to minimize
tungsten electrode contamination. Normally, the high frequency is turned off automatically after arc ignition.
The high frequency power is normally operated continuously with ac to maintain ionization of the arc path as
the arc voltage passes through zero.

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Micro Tig welding with starting current of 0.1 amps for precision welding

Some special power sources provide pulsating direct current with variable frequency. This provision permits
better control of the molten weld pool when welding thin sections, as well as when welding in positions other
than flat. Pulse repetition rates are adjustable as are the pulse profiles. Other pulse features are also controlled.
Power supplies may include electronically controlled features such as "up slopes" and "down slopes", etc. The
latter are necessary to eliminate craters and crater cracking at the beginning and ends of welds or to
accommodate thickness changes, etc. For manual welding much of this power supply sophistication is not
used, as the skilled welder modifies his technique as he observes variations in the weld pool during the
progress of the weld.

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Melting followed by fusion of the weld joint results from the flow of electrons, (the arc current) and the very
high temperature of the arc plasma through which the current passes and which provides the conductance path.
The arc comprises both the current and plasma, along with some generated metallic vapors, etc. Plasma
temperature at the electrode can be tens of thousands of degrees Fahrenheit depending on amperage. Within
the arc region it can be ten to twenty thousand degrees Fahrenheit. Considerable heat is lost by radiation and in
this regard arc efficiency drops. Depending on circuit polarity, the arc may emanate from the tungsten
electrode or from the workpiece. Most often direct current is used but alternating current is advantageous for
welding materials which form refractory oxides, for example aluminum. Due to the complex physics of the
arc, involving electron collisions, pressures, temperature gradients, etc. the arc forms what is sometimes
referred to as an "umbrella" shape. Because of this, arc length must be very short if narrow welds are to be
achieved. Welder skill is therefore challenged to avoid tungsten inclusions in the weld pool and electrode
contamination. Since the arc and plasma is not focusable the concentration of energy in the arc cannot equal
with that developed in the electron and laser beam processes and therefore, GTAW welds due to the lower rate
of energy input are usually wider and have wider heat affected zones. As a result GTAW welds are more prone
to distortion, wider heat affected zones and stresses.

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Semi automatic welding automation and fixtures

We must emphasize this is not intended to imply that GTAW welds are lower quality, they are in fact of
excellent quality. GTAW welding can be called the workhorse of industrial production welding. The low cost
of the equipment and its versatility along with excellent weld quality are the basis of its popularity. In addition,
and due to the slower cooling rate GTAW welds may contain less porosity, lack of fusion or the formation of
brittle martensite than can result from the concentrated energy beams of either the laser or electron beam
processes which are both characterized by very rapid cooling and weld solidification. Rapid cooling is
associated with martensite formation - a brittle phase which has the potential for cracking.

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TIG torch with wire feeding attachment

As in other welding processes there are subtleties. Arc instability, arc blow and wander all seriously affecting
the operation and weld quality can result from magnetic influences, improper electrode preparation, poor
maintenance, improper electrode size, incorrect arc voltage, base metal surface oxidation, inadequate shielding
gas flow rates, coverage and purity. Welds in restricted channel like areas can also reflect the results of arc
instability. Shielding gas contaminated with moisture or oxygen, resulting from hose leaks or moisture on
interior hose surfaces have their destructive effects on weld quality. Efficiency of shielding gas coverage is
important to avoid weld pool and electrode contamination. Physically and chemically dirty joint surfaces
inhibit the "wetting" action of the molten weld pool causing lack of fusion, along with porosity and inclusions.

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Layout of TIG welding system

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Gas tungsten arc welding is a thermal process depending on conducted heat through the weld joint materials to
achieve penetration. In this respect its conductance mode is similar to laser and electron beam. They differ
substantially, however, in the thermal impingement area dimension and their rates of energy input. The
impingement areas of the laser and electron beams may be .010" or .020" in diameter whereas the gas tungsten
arc impinges on an area many times that and, in addition and unlike laser and electron beam is supplemented
by the high temperature radiation and thermal convection of the plasma which result in additional heating of
the areas adjacent to the weld. GTAW penetration is limited to materials less than .250" thick. Beyond this the
weld joint must be prepared by beveling the joint edges forming a "V" or "U" shaped joint geometry when the
workpiece details are butted. Beveling the weld joint by material removal eliminates the need to conduct the
arc heat from the joint surface through to the root. In effect, a crucible is configured and filled by filler wire
addition in the welding operation. Therefore, deeper penetration is dependent not so much on thermal
conductance but by the deposition of filler wire to fill the groove. Welder skill is required. The resultant
unbalanced fusion weld geometry, wide at the top and narrow at the bottom can produce significant distortion.
Restraining fixtures are most often used to reduce this problem. If restraining fixtures or clamps are used
contractual stress generation develops. Depending on the materials and level of stress immediate or delayed
cracking can result.

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Different type of torches

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Several types of tungsten electrodes are used with this process. Thoriated and zirconiated electrodes have
better electron emission characteristics than pure tungsten, making them more suitable for dc operations. The
electrode is normally ground to a point or truncated cone configuration to minimize arc wander. Pure tungsten
has poorer electron emission characteristics but provides better current balance with ac welding. This is
advantageous when welding aluminum and magnesium.

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Effect of electrode tip on penetration profile

Blunt & Sharper Electrodes

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DOFFERENCE BETWEEN SHARPER ELECTRODES AND BLUNTER ELECTRODES

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Electrode Taper

This is usually called out in degrees of included angle (usually anywhere between 14 degrees and 60 degrees).
Below is a summary chart that illustrates how different tapers offer different arc shapes and features:
The equipment needed consists of a welding torch, a welding power source, a source of inert gas with suitable
pressure regulators and flowmeters, a welding face shield, and protective clothing. Electric power
requirements depend upon the type of material and the thicknesses to be welded.

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WELDING OF ALUMINIUM

The difference in welding aluminum from other material is the adhering oxide film on the aluminum surface which influences

the welding behaviour and is a cause of concern. This oxide film has to be removed in order to prevent oxides from being

entrapped in the weld.

The oxide film can be removed by varying the current type or polarity or also through the use of suitable inert gases.For TIG

Welding use pure argon for aluminum materials up to ½" in thickness. Above ½" in thickness, 25 to 75 percent of helium may

be added to make the arc hotter and increase weld penetration.

Aluminum is more often welded using alternating current (AC). In AC welding, the arc's action, breaks up the oxide on the

surface of the aluminum, making welding much easier.

ADVANTAGES

Produces high quality and low distortion welds

Free from spatter

Can be used with or without filler wire

Can be used with a range of premier supplies

Welds almost all metals

Gives precise control of welding heat

Allows excellent control of root pass weld penetration

LIMITATIONS

Produces lower deposition than consumable welding processes. Less economical for section thickness greater than 9.5mm.

Tungsten inclusion if the electrode is allowed to contact the weld pool. Contamination of weld metal if proper shielding of the

filler metal by the gas stream is not maintained. Low tolerance for contaminants on filler or base metal. Extension of

electrodes beyond their normal distances from collet (as with long nozzles) resulting in overheating of the electrode and

porosity in weld pool if gas shielding is not effective . Exceeding the current limit for a given electrode size or type causes

defects.

APPLICATIONS

It is especially used for joining aluminum and magnesium which form refractory oxides. It is extensively used to join stainless

steels, copper, alloy steel and carbon steels. In carbon steels it is primarily used for root pass welding with the application of

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consumable inserts or open root techniques on pipes.

It is widely used to produce high quality joints required in the aerospace and nuclear industries. It is also often used for small

jobs, maintenance and repair work because of its flexibility and ease of control, however requiring great care and skill from

the welder. It can be also be used for spot welding in sheet metal application.

For a in depth technical knowledge of the Tig welding process and applications

visit this page Advanced TIG welding and applications [http://www.arcraftplasma.com/welding/weldingdata/tigwelding.htm]

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Posted 20th October 2015 by Unknown

Labels: Tig welding

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