Tungsten Inert Gas Welding (TIG) is one of the two types of gas shielded arc welding process

as the other one is Metal Inert Gas Welding (MIG). Also in dual-shield mode ofFlux Core Arc
Welding (FCAW), an additional gas supply is provided along with self-shielding of core flux,
due to which FCAW is also listed in gas shielded arc processes. Working principle of TIG
welding is based on the production of arc using high melting and non-consumable tungsten
electrode that is why this process is referred to as (TAGS) tungsten arc gas-shielded which is
also known by other names; argon arc welding, tungsten inert gas and gas tungsten arc
welding. Gas Shielding is used to protect weld puddle from atmospheric contamination. These
gases are transparent so the weld puddle is made visible to a welder. Some distinct features
of TIG process are

In TIG no flux is used and there is no fear of corrosion due to flux entrapment.
No slagging that contributes to elimination of post weld cleaning.
Since there is no spark and fumes, and that is why sound weld with perfect definition
is obtained.

A non-consumable tungsten electrode is used to produce an arc of considerable high

temperature that assists to melt work metal. Air is driven out due to the envelope of inert gas
that prevents the weldment, tungsten electrode and heat affected zone from oxidation.
Contrary to MIG, tungsten electrode is not consumed rather it provides arc to melt the
additional filler metal. Likewise oxyacetylene welding, filler metal is fed to the weld puddle.
Normally there are two modes in TIG; semi-automatic or automatic. In semiautomatic, operator has to configure current and gas flow settings and then manually deals
with the torch and filler road. However in automatic the operator sets the travel speed, length
of arc, gas flow rate, filler rod position and then observes the operation and controls whereby
it is needed.
In early times TIG was first introduced to weld magnesium to minimize rapid corrosion
problems. The technique was successfully applied to achieve best results with no resulting
corrosion. This process was introduced with distinct features as compared to other arc
processes. For shielding, gas flow rate can be controlled by flow rate and manifold. During
welding, gas flow not only shields the weld and filler metal but also protects the torch. There is
also a gas delay feature that permits gas to flow for preset time, after the welding current has
been shut off.
TIG is applied in both welding of ferrous and non-ferrous metals with wide range of thickness
not above 8mm. Both alternating (AC) and direct (DC) current supplies are used with current
of range 15 to 350 amps. With the use of small diameter electrodes and suitable current
range, the process is applied in both repair work and new manufacturing. Although it is
comparatively slower than other arc processes but it produce high quality welds with perfect
definition in aluminum, carbon steel and stainless steel family. DC source is used for welding
of stainless steel, carbon steel, nickel and copper alloys. On the other hand AC is suitable for
the welding of Aluminum and its alloys.

Equipment
A. TIG Torch
Different size of torches are available for different current carrying capacities. Its
assembly includes a switch for different welding operations. The torch casing holds gas
nozzles and electrode.
B. Additional Features
1. Water cooling system
Welding with high amperages means cooling is required. A water cooling system is
installed in which water is circulated through the torch to keep it cool. Older systems were
connected with additional cooling system but now a days it is installed inside the modified
equipment. The water flow is controlled either by foot pedal or torch.
2. DC suppression
In Aluminum and magnesium alloys welding, formation of surface oxide is major
concern. In Aluminum welding as the arc is formed between the tungsten and aluminum
(dissimilar metals) chances are that AC is converted to DC mode. So a DC suppressor is
used to prevent the conversion of AC to DC.
3. Contactor
This feature puts the arc to be extinguished when delay shielding is required for
cooling purposes. In this way it not only protects weld but also provides means of safety to the
welder. This process is also controlled by torch and foot pedal.
4. Arc Initiation
Arc initiation by touching the electrode with the base metal can cause serious
problems of contamination and may lead to arc un-stability. Obviously tungsten inclusion can
cause localized hard spots. On the other hand the transfer of base metal to tungsten
electrode can also cause contamination and consequently un-stabilize the arc. For the
electrode not to touch with the work piece, high frequency spark is produced that causes
some sort of ionization in spark gap. The welding current continues to flow due to this ionized
spark gap. This feature also contributes to enhance the life span of tungsten electrode. Listed
below are the arc initiation methods that are normally being used in modern equipment.
a. Scratch start
In this method the electrode is brought down to the work piece and gently scratched to
initiate the arc. As it is stated above that the slight contact can cause the problem of
contamination. This method is applied only in those applications where contamination is less
and no serious problems of weld are generated.

b. Lift up
In this method the electrode is brought down to make contact with work at the initial
point of welding. Torch switch is pressed that creates contact and still no current is produced.
When the electrode is lifted up making a gap, the current continues to flow and rapidly
increases to the pre-set value. This rapid increase in current is referred to as popular term
slope up.
c. Slope up
Slope up is the rapid rise of welding current to preset current on the power source. By
the use of switch the welder can set the time required for the rise of current to the selected
amperages. This feature offers less contamination and reduces the danger of burning thin
sheets at the initial point of welding.
d. Slope down
Slope down is the gradual decrease of welding current to zero. It is referred to as the
time taken to decrease the current until the arc is extinguished. Well this feature is used to fill
the crater (weld imperfection) at the end of the weld. Normally this function is operated with
the help of torch switch and foot pedal.
C. Electrode used in TIG
Tungsten is high melting point metal which is about 3000 degree Celsius. In TIG
process pure tungsten with its best thermal and electrical conductivity is used. Now a days
alloyed tungsten with 1-2% thorium and zirconium is applied for better arc stability and
improved electrode life. Two types of alloyed tungsten electrodes are; thorated electrode for
DC mode and zirconated for AC mode. It is also noticeable that electrode diameter depends
on current polarity.
Electrode Grinding
Electrode grinding is one of the major concern in achieving consistent performance in
welds. Electrodes are ground according to the application (joint). There are two ways for
electrode grinding; machine grinding and manual grinding. Machine grinding results in
consistent grinding. However care must be take while manual grinding.
Electrode shape
1. Electrode is usually ground to required vertex angle. For DC usage the electrode is ground
to the length of 1-3 times the diameter of electrode.
Point length of electrode = 1-3 x Diameter of electrode.

In this way the lower the current the longer will be the point length. Electrodes are available
normally within the diameter range of 0.8, 1.6, 3.2, 4.0 and 6.4 mm.
2. For AC usage the side of electrode end is ground to 45 degree, remaining the front side to
be flat. This gives the spherical shape as shown in the figure.

Electrode installation in torch

Well this one is simple. The electrode is installed in torch and held tightly with the help of
grippers knows as sockets. They can grip and hold the electrodes of various diameters.
D. Gas Nozzles
These nozzles are of high temperature ceramic materials to bear high welding
temperature. As it is stated above some nozzles are equipped with water cool system. Only
the right choice of nozzle size gives better protection of weldment, weld pool and filler
material. Various shapes of nozzles are available for different kinds of jobs. Small size
nozzles are available for confined areas. Long shapes are available for deep groove joints.
E. Gas lens
Gas lens is provided to prevent the turbulence of gas flow. Poor gas flow may not give
good shielding service hence gas lens is used to provide consistent and smooth gas flow to
shield the weld puddle. With the help of gas lens, electrode extension can also be achieved
for access of complicated areas.