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TIG Welding
Rev 2 April 2013
TIG Welding
Copyright TWI Ltd 2013
12 TIG Welding
12.1 Process characteristics
In the US the TIG process is also called gas tungsten arc welding (GTAW).
Melting is produced by heating with an arc struck between a non-
consumable tungsten electrode and the workpiece. An inert gas shields 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).
Tungsten is used because it has a melting point of 3370°C, well above any
other common metal.
Welding current.
Current type and polarity.
Travel speed.
Shape of tungsten electrode tip and vertex angle.
Shielding gas flow rate.
Electrode extension.
12-1
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TIG Welding
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(A.C.)
Current
DC-ve AC DC+ve
type/polarity
Heat 70% at work 50% at work 30% at work
balance 30% at electrode 50% at electrode 70% at electrode
Weld profile Deep, narrow Medium Shallow, wide
Cleaning No Yes – every half cycle Yes
action
Electrode Excellent Good Poor
capacity (3.2mm/400A) (3.2mm/225A) (6.4mm/120A)
12-2
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TIG Welding
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Pure tungsten electrodes are used when welding light metals with AC
because they maintain a clean balled end, but 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 and 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 and
operate successfully with DC or AC and as cerium and lanthanum are
not radioactive, they have been used as replacements for thoriated
electrodes.
Zirconiated electrodes are alloyed with zirconium oxide with operating
characteristics between the thoriated types and pure tungsten. They are
able to retain a balled end during welding, so are recommended for AC
welding. They have a high resistance to contamination so are used for
high integrity welds where tungsten inclusions must be avoided.
12-3
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TIG Welding
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Argon.
Helium.
Mixtures of argon and helium.
Note: For austenitic stainless steels and some cupro-nickel alloys, argon
with up to ~5% hydrogen improves penetration and reduces porosity.
12-4
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TIG Welding
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Back purging
It is necessary to protect the back of the weld from excessive oxidation
during TIG welding, achieved by using a purge gas, usually pure argon.
For pipe welding spools 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. For purging large systems soluble dams or bungs are required
and can it can be a complex operation.
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 so there is positive flow (typically
~4 l/min).
Back purging should continue until two or more layers of weld have been
deposited.
12-5
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TIG Welding
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Electrode
Stickout extension
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,
causing melting and lead to tungsten inclusions.
As a general rule stickout length should be 2-3 times the electrode
diameter.
Thermal shock to the tungsten causing small fragments to enter the weld
pool is a common cause of tungsten inclusions and is 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 so
the tungsten is heated more slowly and gently.
12-6
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TIG Welding
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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 items such as airframes and
rocket motor cases.
12.7 Advantages
Produces superior quality welds with very low levels of diffusible
hydrogen so there is less danger of cold cracking.
No 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, manufacturing semiconductors, etc.
Can be used with filler metal and on thin sections without filler and can
produces welds at relatively high speed.
Enables welding variables to be accurately controlled and is particularly
good for controlling weld root penetration in all welding.
Can weld almost all weldable metals including dissimilar joints but
welding in position is not generally used for those with low melting points
such as lead and tin. Especially useful in welding reactive metals with
very stable oxides such as aluminium, magnesium, titanium and
zirconium.
The heat source and filler metal additions are controlled independently
so it is very good for joining thin base metals.
12.8 Disadvantages
Gives low deposition rates compared with other arc welding processes.
Need 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 so may not
be suitable for site/field welding.
Tungsten inclusions can occur if the electrode contacts the weld pool.
No cleaning action so low tolerance for contaminants on filler or base
metals.
12-7
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