［溶接学会論文集 第 31 巻 第４号 p.

18s-21s （2013）］

Study for TIG-MIG Hybrid Welding Process

- Experimental Consideration for Optimum Torch Configuration -

by Shuhei Kanemaru**, Tomoaki Sasaki**, Toyoyuki Sato**, Hisashi Mishima***, Shinichi Tashiro***
and Manabu Tanaka***

On TIG-MIG hybrid welding process, the MIG arc can keep stability even in pure inert shielding gas by the effect of hybridization with
TIG arc and it becomes possible to achieve the both merits of high quality as well as TIG and high efficiency as well as MIG. In this report,
we considered about optimum torch configuration on this process for practical application. As a result, following findings were obtained:
(1) More than +45r MIG torch angle is needed to keep forehead angle of MIG arc under condition that quite large repulsion occurs. (2)
Although there is not seen deciding difference for bead shape and penetration by the change of torch angle, TIG 0r/MIG+45r is the best
configuration relatively for the penetration shape and flatness of bead shape. (3) Based on the consideration, original torch for TIG-MIG
hybrid welding process was produced and it was confirmed the good weldability on practical joint.

Key Words: (TIG welding), (MIG welding), (Pure Argon shielding gas), (Hybridization), (High efficiency), (High quality)

1. Introduction In this report, we investigated the influence of torch angle of

We study about TIG-MIG hybrid welding process which can
stabilize MIG arc even in pure Ar shielded condition thus it is
possible to achieve the both merits of high quality as well as TIG
and high efficiency as well as MIG. On the base of experimental
and numerical simulation, we showed the results as follows in
previous reports.
(1) The condition that TIG current is larger than MIG current is
needed for arc stability and it is expected that the additional
1)
TIG current can control penetration in this process .
(2) The direct current path generates between TIG and MIG
electrodes through high temperature arc plasma depends on
its electro conductivity, and there is the possibility that this
phenomena contributes to stabilization of the pure Ar shielded
MIG arc2-3).
(3) For the torch angle and distance, it is necessary to position
nearby distance and cross each other in suitable condition
range for keeping arc stability1).
Determination of the optimum configuration for the torches to
obtain the good weldability is very important. It is needed the rich
tolerance of the condition range for the variable welding
conditions such as thickness and type of joint, inclined position
for multi-pass welding of practical application. Generally, in the
many case of the hybrid welding process which combines several
heat sources, includes this process, the parameter of hybridization
tends to increase much rather than ordinary process. As a result,
the influence of parameter becomes complicated and decision of
suitable condition becomes difficult. Therefore, determination of
the suitable configuration of torches is important to treat useful
the hybrid process4).
TIG and MIG on the welding property such as the arc shape, bead
appearance, and penetration shape. Because the complication of
hybrid process increases with the number of treated parameter, it
is important to narrow down the parameter for purpose of
consideration. The purpose of this consideration is the
determination of optimum configuration which has compact
structure and tolerance for the certain range of current condition.
Therefore, the distance between TIG and MIG arc was fixed to
4mm as basic parameter in previous reports1) for compact
structure and the influence of torch angle and current condition
was discussed mainly. Based on the results, the optimum
configuration for practical execution was decided. At last, the
original torch which has unified and fixed structure on decided
torch angle for TIG-MIG hybrid welding process was produced
and its weldability was confirmed on practical joint.
2. Experimental procedure
Fig.1 shows the sizes, configuration of the experimental
apparatus including position from front to rear, and polarity of
TIG and MIG electrodes. Table1 shows the welding conditions in
this study. The configuration of the torches were set up based on
the distance between the crossing positions of electrodes-axis and
surface on base metal shown as ͆Distance between TIG and MIG
arc͇, thus the leading TIG and trailing MIG were configured.
Concerning the arc ignition steps, TIG arc was started first and
weld pool was formed on the surface of base metal, and then MIG
arc was started. Stable arc is obtained even in pure inert shielding
gas by hybridization of TIG and MIG arc on suitable condition.
 *Received: 2012.12.26
**
Member, TAIYO NIPPON SANSO Corporation
***
Member, Joining and Welding Research Institute Osaka
University
 溶 接 学 会 論 文 集 第 31 巻（2013）第４号 19s
     ◊✲ㄽᩥ

Torch angle
A A The experiment was performed in order to consider the
䠇 optimum configuration of TIG and MIG torches. TIG torch angle
䠉
Welding 䠇
direction
V
V was set vertical and the distance between TIG and MIG arc set

TIG

MIG power
TIG power

IG
TIG arc
4mm to constitute the structure to simple and compact. TIG

source
source

M
length 䠉 MIG wire
㸸5mm extension vertical configuration also seems to be desirable for control of
䠇 㸸25mm
torch axis in the case of automation. MIG torch angle changed in
䠇 䠉
䠇 䠉
the range of +30㹼60r and MIG current was fixed on about
Distance between TIG and MIG arc㸸4mm
290A to set the metal transfer mode to splay transfer which can
Fig.1 Schematic illustration of experimental set up
be expected the large stiffness of arc for the repulsion from TIG
Table1 Welding condition arc.
ͤSpecial specification for TIG output characteristic

Base metal Stainless steel type304, t12

DCEN, 2%La2O3 ȭ4.0mm, The experimental results were considered about the influence
TIG electrode on the welding property such as degree of repulsion, bead shape,
tip angle:30°, tip diamiter:1mm
MIG wire DCEP, type308 ȭ1.2mm and penetration. To compare with the case of symmetrical TIG
Shielding gas Ar and MIG torch angle TIG-30°/MIG+30° (Fig.3) as basic
ͤ
TIG㸸OTC DP500 condition in previous reports, the results of this condition was
Power source
MIG㸸OTC DP500 also confirmed.
Current (TIG㸭MIG) 300㹼500A㸭290A Based on above mentioned matter, we decided the torch angle
Wire feed speed 9.5㹼11m/min and produced the original torch for TIG-MIG hybrid welding
Welding speed 30㹼40cm/min process which has fixed and unified structure. At last, we
Distance between
4mm confirmed that it is possible that good weldability is obtained on
TIG and MIG arc
application for practical joint including inclined position such as
TIG arc length 5mm
multi pass fillet weld by this original torch.
MIG wire extension 25mm
(a) 0°㸭㸩30㹼60°
Torch angle 3. Results and Discussion
(b)㸫30°㸭㸩30°
(TIG㸭MIG)
㸦optimized㸸0°㸭㸩45°㸧
Fig.4 shows the image of high speed camera picture and the
Torch angle Torch angle bead appearance under each condition of MIG torch angel. In
+30㼻䡚+60㼻
䠉30㼻 䠇30㼻 these conditions, TIG torch angle was fixed vertical. The
Welding direction of MIG arc changed from axis of MIG wire electrode
direction Welding
TIG

TIG

direction
G

due to effect of repulsion between TIG and MIG arc, and it

MI
IG
M

directed to backward on the torch angle TIG0ᶟ/ MIG+35ᶟ. It is

thought that direction of MIG arc is determined by the balance
between the two forces described below:
(a) TIG vertical (b) Symmetrical
(1) Force to backward from repulsion effect caused by
Fig.3 Two patterns of torch angle configuration
electromagnetic interaction with leading TIG arc

35° Default direction 45

5° 55
5°
of MIG wire
Final direction
of MIG arc

TIG450A/MIG285A-30cm/min TIG450A/MIG280-30cm/min TIG450A/MIG310A-30cm/min

(a) TIG 0°㸭MIG +35° (b) TIG 0°㸭MIG +45° (c) TIG 0°㸭MIG +55°
Fig.4 Comparison of the image of high speed camera and bead appearance each torch angle
 20s 研究論文  KANEMARU et al.: Study for TIG-MIG Hybrid Welding Process- Experimental Consideration for Optimum ∼


(2) Force to forward from stiffness of trailing MIG arc having

forehead angle.
It seems that the direction of MIG arc, namely melting zone TIG

of MIG wire, influences droplet transfer and bead formation. In 500A

d:5.2mm d:4.8mm d:3.7mm d:4.9mm
the previous reports for multiple electrode welding processes H:2.8 mm H:2.9mm H:2.9mm H:3.2mm
W:13.8mm W:14.5mm W:13.7mm W:14.0mm
such as the tandem GMA4, 5) and multiple electrode submerged
arc6), it is shown that trailing MIG arc is desired to direct forward
in order to avoid formation of humping bead. The humping bead
TIG
is formed by irregularly backward flow of weld pool in the
400A
conditions of high speed and high current welding, and then, d:4.6mm d:4.0mm d:2.9mm d:4.0mm
trailing MIG arc prevents the formation of it by easing the flow H:3.1mm H:2.9mm H:3.1mm H:3.2mm
W:12.6mm W:13.9mm W:13.5mm W:12.9mm
by its arc force and filling the weld metal to molten pool.

6
TIG300㹼500A/MIG290A-40cm/min TIG
300A
Penetration depth (mm)

5 d:3.8mm d:3.4mm d:2.2mm d:3.1mm

H:3.4mm H:3.0mm H:3.5mm H:3.4mm
4 W:11.4mm W:12.7mm W:12.2mm W:11.7mm
TIG 0r TIG 0r TIG 0r TIG -30r
3 / MIG +30r / MIG+45r / MIG+60r / MIG+30r
TIG 500A
2 TIG 400A Penetration depth Fig.7 Cross section on each torch angle (MIG290A)
TIG 300A d: penetration depth, H: reinforcement height, W:bead width
1
penetration depth was almost same about 1.5mm in the range of
0㼻
+3 /

5㼻
+4 /

0㼻 /
0㼻
+6 /
IG 0㼻

IG 0㼻

+3 0㼻
IG 0㼻
M IG

M IG

TIG current 300῍500A. The value of penetration depth was

IG -3
M IG

M IG
T

large as MIG torch angle was small and the maximum depth was
Fig.5 Change of penetration depth by torch angle
obtained on condition TIG0ᶟ/MIG+30ᶟ on the each condition
W TIG 500A of TIG current.
0.35
H TIG 400A Fig.6 shows the change of size for bead shape by TIG current
TIG 300A under the each condition. To evaluate the extent of flatness for
0.30
bead shape, H/W was compared on each condition. Although
H䠋W 䠄䇲䠅

there was not significant difference, the most flat shape was
0.25
obtained on torch angle TIG0ᶟ/MIG+45ᶟ due to increase of
0.20 bead width (W) and decrease of reinforcement height(H). The
results of TIG-30ᶟ/MIG+30ᶟ also behave like the results on
TIG300㹼500A/MIG290A-40cm/min
torch angle TIG0 ᶟ /MIG+30 ῍ 60 ᶟ without significant
0.15
difference.
0㼻
+3㼻 /

5㼻
+4 / /

0㼻 / /
0㼻
+6㼻 /
0㼻

0㼻
IG 0㼻/

IG 0㼻/
M IG㼻

IG 㼻

+3 㼻
M IG㼻

㼻
M IG

IG -3

Fig.7 shows the picture of cross section under the each

M IG
T

Fig.6 Change of bead shape by torch angle
Based on the idea mentioned above, we considered that the
MIG torch angle needs to be more than +45 ᶟ as suitable
configuration to keep forehead angle of direction of MIG arc even
in the condition that the repulsion is quite large (TIG 450A/MIG
290A(Fig.4(b))
Fig.5 shows the change of penetration depth by TIG current
value under each condition for torch angle and TIG current value.
The tendency for increase of penetration depth by TIG current
was almost same on each torch angle, and the range of change for
condition. The finger-like penetration was obtained on torch
angle TIG0ᶟ/MIG+30ᶟ especially, which has the largest value
of penetration depth in the results showed above. It seems that
extreme finger shape is not suitable to avoid the defect such as
lack of fusion. On the other hand, the broad shape of penetration
was obtained on torch angle TIG0ᶟ/MIG+60ᶟ. However, there
was the deviation for center of penetration. This deviation seems
to be caused by deflection of MIG wire and it is expected to
improve from the effect that the direction of MIG arc is fixed by
the force balance between the repulsion from TIG arc and the
stiffness of MIG arc.
 溶 接 学 会 論 文 集
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These results suggested that MIG torch angle changes not only
appearance of arc shape but the shape of bead and penetration
even in same TIG/MIG current condition. There was not seen the
remarkable difference which can decides the right or wrong of
weld bead. However, in other words, it can be considered that
there is the rich tolerance about torch configuration for welding
results.
As relative optimum configurations, TIG0ᶟ/MIG+45ᶟ was
selected from the following reasons:
(1) MIG torch angle needs to be more than +45ᶟ to keep
forehead angle under the large repulsion condition.
(2) The deviation for center of penetration is expected to be
improved effectively by fixing due to the balance between
the repulsion from TIG arc and stiffness of MIG arc.
(3) The most flat bead shape evaluated from H/W was
obtained.
Based on these considerations, we produced the original torch.
Appearance of the torch is shown in fig.8. For example, Fig.9
shows the result of application for the fillet joint by using original
torch. Good welded joint without oxidation was obtained on
multi-layer welding even in welding position having inclined
angle by unified structure of torch and nozzle.
Fig.8 Original Torch for TIG-MIG hybrid welding
Inclined angle 㸸(1)50°(2)30°(3)45°
Welding speed 㸸40cm/min
Joint 㸸type304 t6 fillet weld
Current 㸸TIG340A / MIG280A
Fig.9 Results of application for fillet joint by original torch
                                          
第 31 巻（2013）第４号 21s
4. Conclusions
In this report, the following conclusions were obtained.
(1) We considered about MIG torch angle to keep forehead angle
of MIG arc under the influence of repulsion from TIG arc,
and it was decided on TIG0 r/MIG+45r based on the
results of observation for the arc shape.
(2) The bead shape characteristics such as penetration, bead width,
and reinforcement height were considered on each torch angle.
There was not remarkable deference thus it can be expected
that this process has rich tolerance for torch angle condition.
It was confirmed that selected angle(TIG0r/MIG+45r) was
relatively good condition for penetration depth, shape, and
flatness of bead shape evaluated by cross section.
(3) The original torch for TIG-MIG hybrid welding process which
has fixed and unified structure on optimized configuration
was produced, and it was confirmed the good weldability on
practical joint welding.
References
1)  S.Kanemaru, T.Sasaki, T.Sato, M.Tanaka: Basic Study on
TIG-MIG Hybrid Welding Process, Quarterly Journal of Japan
Welding Society, Vol.30, No.1 (2012), pp29-34. (in Japanese)
2) S.Kanemaru, T.Sasaki, T.Sato, H.Mishima, S.Tashiro, M.Tanaka:
3D Numerical Analysis model for TIG-MIG Hybrid Welding
Process, Quarterly Journal of Japan Welding Society, Vol.30,
No.4 (2012), pp306-312. (in Japanese)
3) S.Kanemaru, T.Sasaki, T.Sato, H.Mishima, S.Tashiro, M.Tanaka:
Study for the Arc Phenomena of TIG-MIG Hybrid Welding
Process by 3D Numerical Analysis Model, Quarterly Journal of
Japan Welding Society, Vol.30, No.4 (2012), pp323-330. (in
Japanese)
4)  T.Ueyama, T.Ohnawa, M.Tanaka, K.Nakata: Effect of Torch
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Pulsed GMA Welding Process, Quarterly Journal of Japan
Welding Society Vol.23, No,3 (2005), pp383-391. (in Japanese)
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Current on High Speed Welding Bead Formation in Tandem
Pulsed GMA Welding Process, Quarterly Journal of Japan
Welding Society, Vol.23, No.3 (2005), pp392-397. (in Japanese)
6㸧 Y.Ito, M.Ikeda, N.Yamanouchi: The Studies of Bead Formation in
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