1

Process Characteristics
In the USA the TIG process is also called gas tungsten arc welding (GTAW). TIG welding is a process where melting is produced by heating with an arc struck between a non-consumable tungsten electrode and the workpiece. An inert gas is used to shield the electrode and weld zone to prevent oxidation of the tungsten electrode and atmospheric contamination of the weld and hot filler wire (as shown below).

Manual TIG welding

Tungsten is used because it has a melting point of 3370C, which is well above any other common metal.

Process Variables
The main variables in TIG welding are: Welding current Current type and polarity Travel speed Shape of tungsten electrode tip and vertex angle Shielding gas flow rate Electrode extension

Each of these variables is considered in more detail in the following subsections.

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2.1

Welding current
Weld penetration is directly related to welding current If the welding current is too low, the electrode tip will not be properly heated and an unstable arc may result If the welding current is too high, the electrode tip might overheat and melt, leading to tungsten inclusions

2.2

Current type and polarity

The best welding results are usually obtained with DC electrode negative Refractory oxides such as those of aluminium or magnesium can hinder fusion but these can be removed by using AC or DC electrode positive With a DC positively connected electrode, heat is concentrated at the electrode tip and therefore the electrode needs to be of greater diameter than when using DC negative if overheating of the tungsten is to be avoided. A water cooled torch is recommended if DC positive is used The current carrying capacity of a DC positive electrode is about one tenth that of a negative one and it is therefore limited to welding sections

Ions

Electrons

Ions

Electrons Ions

Electrons

Current type/polarity Heat balance Weld profile Cleaning action Electrode capacity

DCEN 70% at work 30% at electrode Deep, narrow No Excellent (3.2mm/400A)

AC 50% at work 50% at electrode Medium Yes every half cycle Good (3.2mm/225A)

DCEP 30% at work 70% at electrode Shallow, wide Yes Poor (6.4mm/120A)

2.3

Travel speed
Travel speed affects both weld width and penetration but the effect on width is more pronounced. Increasing the travel speed reduces the penetration and width Reducing the travel speed increases the penetration and width

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2.4

Tungsten electrode types

Different types of tungsten electrodes can be used to suit different applications: Pure tungsten electrodes are used when welding light metals with AC because of their ability to maintain a clean balled end. However they possess poor arc initiation and stability in AC mode compared with other types Thoriated electrodes are alloyed with thorium oxide (thoria) to improve arc initiation. They have higher current carrying capacity than pure tungsten electrodes and maintain a sharp tip for longer. Unfortunately, thoria is slightly radioactive (emitting radiation) and the dust generated during tip grinding should not be inhaled. Electrode grinding machines used for thoriated tungsten grinding should be fitted with a dust extraction system. Ceriated and lanthaniated electrodes are alloyed with cerium and lanthanum oxides, for the same reason as thoriated electrodes. They operate successfully with DC or AC but since cerium and lanthanum are not radioactive, these types have been used as replacements for thoriated electrodes Zirconiated electrodes are alloyed with zirconium oxide. Operating characteristics of these electrodes fall between the thoriated types and pure tungsten. However, since they are able to retain a balled end during welding, they are recommended for AC welding. Also, they have a high resistance to contamination and so are used for high integrity welds where tungsten inclusions must be avoided.

2.5

Shape of tungsten electrode tip

With DC electrode negative, thoriated, ceriated or lanthanated tungsten electrodes are used with the end ground to a specific angle (the electrode tip or vertex angle shown below). As a general rule, the length of the ground portion of the tip of the electrode should have a length equal to approximately 2 to 2.5 times the electrode diameter. The tip of the electrode is ground flat to minimise the risk of it breaking off when the arc is initiated or during welding (shown below). If the vertex angle is increased, the penetration increases. If the vertex angle is decreased, bead width increases. For AC welding, pure or zirconiated tungsten electrodes are used. These are used with a hemispherical (balled) end (as shown below). In order to produce a balled end the electrode is ground, an arc initiated and the current increased until it melts the tip of the electrode.

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Electrode tip angle Electrode tip with flat Electrode tip with a (or vertex angle) end balled end

2.6

Shielding gases
The following inert gases can be used as shielding gases for TIG welding: Argon Helium Mixtures of argon and helium Note: For austenitic stainless steels and some cupro-nickel alloys, argon with up to ~5% hydrogen may be used to improve penetration and reduce porosity
Argon Lower than with helium, which can be helpful when welding thin sections. Less change in arc voltage with variations in arc length. Lower than with helium, which gives reduced penetration. Argon is heavier than air, so requires less gas to shield in the flat and horizontal positions. Also, better draught resistance. Obtained from the atmosphere by the separation of liquefied air lower cost and greater availability. Performance item Arc voltage Helium Higher than with argon. Arc is hotter which is helpful in welding thick sections and viscous metals (eg nickel). High, which can be of advantage when welding metals with high thermal conductivity and thick materials. Helium is lighter than air and requires more gas to properly shield the weld. Exception: overhead welding. Obtained by separation from natural gas lower availability and higher cost.

Heating power of the arc

Protection of weld

Availability and cost

Characteristics of argon and helium shielding gases for TIG welding

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2.6.1

Shielding gas flow rate If the gas flow rate is too-low, the shielding gas cannot remove the air from the weld area and this may result in porosity and contamination. If the gas flow rate is too high, turbulence occurs at the base of the shielding gas column. Air tends to be sucked in from the surrounding atmosphere and this may also lead to porosity and contamination. Shielding gas flow rates are typically in the range ~10 to ~12 l/min rate too low

Flow rate too low

Flow rate too high

2.6.2

Back purging It is necessary to protect the back of the weld from excessive oxidation during TIG welding and this is achieved by the use a purge gas usually pure argon. For pipe welding, it is relatively easy to purge the pipe bore, but for plate/sheet welding it is necessary to use a purge channel or sometimes another operator positions and moves a back purge nozzle as the weld progresses. The initial stage of back purging is to exclude all the air at the back of the weld and having allowed sufficient time for this the flow rate should be reduced prior to starting to weld such that there is positive flow (typically ~4 l/min). Back purging should continue until two or more layers of weld have been deposited. For C and C-Mn steels it is possible to make satisfactory welds without a back purge.

2.7

Electrode extension
Electrode extension is the distance from the contact tube to the tungsten tip Because the contact tube is recessed inside the gas nozzle, this parameter can be checked indirectly by measuring the stickout length as shown below

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Electrode extension Stickout

If the electrode extension is too short, the electrode tip will not be adequately heated leading to an unstable arc If the electrode extension is too long, the electrode tip might overheat, cause melting and lead to tungsten inclusions As a general rule, stickout length should be 2 to 3 times the electrode diameter

Filler Wires
It is usual practice to use filler wires that have a similar composition to the parent metal but they may contain small additions of elements that will combine with any oxygen and nitrogen present.

Tungsten Inclusions
Small fragments of tungsten that enter a weld will always show up on radiographs because of the relatively high density of this metal and for most applications will not be acceptable. Thermal shock to the tungsten causing small fragments to enter the weld pool is a common cause of tungsten inclusions and is the reason why modern power sources have a current slope-up device to minimise this risk. This device allows the current to rise to the set value over a short period and so the tungsten is heated more slowly and gently.

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Crater Cracking
Crater cracking is one form of solidification cracking and some filler metals can be sensitive to it. Modern power sources have a current slope-out device so that at the end of a weld when the welder switches off the current it reduces gradually and the weld pool gets smaller and shallower. This means that the weld pool has a more favourable shape when it finally solidifies and crater cracking can be avoided.

Common Applications of the TIG Process

These include autogenous welding of longitudinal seams in thin walled pipes and tubes, in stainless steel and other alloys, on continuous forming mills. Using filler wires, TIG is used for making high quality joints in heavier gauge pipe and tubing for the chemical, petroleum and power generating industries. It is also used in the aerospace industry for such items as airframes and rocket motor cases.

Advantages of the TIG process

Produces superior quality welds, with very low levels of diffusible hydrogen so there is less danger of cold cracking. Does not give either weld spatter or slag inclusions which makes it particularly suitable for applications that require a high degree of cleanliness (eg pipework for the food and drinks industry, semiconductors manufacturing, etc). Can be used with filler metal and on thin sections without filler, it can produce welds at relatively high speed. Enables welding variables to be accurately controlled and is particularly good for controlling weld root penetration in all positions of welding. Can weld almost all weldable metals, including dissimilar joints, but it is not generally used for those with low melting points such as lead and tin. The method is especially useful in welding the reactive metals with very stable oxides such as aluminium, magnesium, titanium and zirconium. The heat source and filler metal additions are controlled independently and thus it is very good for joining thin base metals.

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Disadvantages of the TIG Process

Gives low deposition rates compared with other arc welding processes. Need for higher dexterity and welder co-ordination than with MIG/MAG or MMA welding. Less economical than MMA or MIG/MAG for sections thicker than ~10mm. Difficult to fully shield the weld zone in draughty conditions and so may not be suitable for site/field welding Tungsten inclusions can occur if the electrode is allowed to contact the weld pool. The process does not have any cleaning action and so has low tolerance for contaminants on filler or base metals.

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