CSWIP 3.

1 Welding Inspection

Tungsten Inert Gas

or
Gas Tungsten Arc Welding
TWI Training & Examination Services

Course Reference WIS 5

Tungsten Inert Gas Welding

The TIG welding process was first developed in the USA
during the 2nd world war for the welding of aluminum alloys
The process uses a non-consumable tungsten electrode
The process requires a high level of welder skill
The process produces very high quality welds.
The TIG process is considered as a slow process compared to
other arc welding processes
The arc may be initiated by a high frequency to avoid scratch
starting, which could cause contamination of the tungsten and
weld

TIG - Principle of operation

Tungsten Inert Gas Welding

USA: GTAW
Ceramic
Nozzle

Welding Torch

Current Conductor

Shielding gas

Tungsten
Electrode
Contact Tube

Gas Shield
Filler Wire

Arc

Weld Pool

TIG power source

POWER SOURCE
440v 50Hz 3 phase or
240v single phase input

Transformers for AC aluminium alloys

Rectifiers for DC - steels
Transformer/rectifier for AC/DC
Inverters for AC/DC more portable - expensive

TORCH

Sizes/types vary depending on current/application

TORCH HOSE

Flexible may carry current, gas, cooling water.

RETURN LEAD

Note that current actually flows from this lead

INERT GAS SUPPLY

(Cylinder & regulator)

Correct type for application.(ar, he, ar/he mixture)

Argon/hydrogen for austenitic stainless steel

FLOWMETER
(graduated in ltr/min)

To deliver correct gas flow (velocity) depending on welding

position and joint configuration.

Equipment for TIG

Power control
panel
Power return
cable

Torch
assemblies
Tungsten
electrodes

Transformer/
Rectifier
Inverter
power source

Power control
panel
Power cable
Flow-meter

Equipment for TIG

Power source control panel
Ammeter
Start method
Start/stop current
AC balance
2/4 stroke

Remote
control
Welding
current
Postflow
(Preflow)
Slope up
Slope down

Pulse ON/OFF

Background
current

Pulse frequency

Peak current

ON/OFF switch

Current type
& polarity

Courtesy of Lincoln Electric

ARC CHARACTERISTICS
Constant Current/Amperage Characteristic
Large change in voltage =
Smaller change in amperage

OCV

Volts
Large arc gap
Welding Voltage
Small arc
gap

Amps

TIG Torch

Torch types:

Gas cooled: cheap, simple, large size, short life for

component parts
Water cooled: recommended over 150A, expensive, complex,
small size, longer life for component parts

TIG Torch
Tungsten
electrode
Torch
cap/tungsten
housing

Electrode
collet

Collet
holder

Torch
body
Ceramic
nozzle
On/off
switch

TIG Torch
Gas lenses
Stainless steel
wire sieve
Thread for
gas nozzle
Thread for
torch body
reduces eddies in the gas flow
extends the length of the laminar flow

prevents contamination
highly recommended in case of reactive
metals (e.g. Ti, Al)

Electrode tip for DCEN

2-2,5 times
electrode diameter

Penetration
increase
Increase
Vertex
angle
Decrease
Bead width
Electrode tip prepared increase Electrode tip prepared for
for low current welding
high current welding

Electrode tip for AC

Electrode tip ground

Electrode tip ground

and then conditioned

TIG Welding Variables

Tungsten electrodes
The electrode diameter, type and vertex angle are all critical
factors considered as essential variables. The vertex angle is as
shown
AC
DC -ve

Vetex angle
Note: too fine an angle will
promote melting of the
electrodes tip

Note: when welding

aluminium with AC current,
the tungsten end is
chamfered and forms a ball
end when welding

Choosing the proper electrode

Polarity Influence cathodic cleaning effect

Tungsten Electrodes
Old types:
Thoriated: DC electrode -ve - steels and most metals
1% thoriated + tungsten for higher current values
2% thoriated for lower current values
Zirconiated: AC - aluminum alloys and magnesium

New types:
Cerium: DC electrode -ve - steels and most metals
Lanthanum: AC - Aluminum alloys and magnesium

Tungsten electrode types

Pure tungsten electrodes:
colour code - green
no alloy additions
low current carrying capacity
maintains a clean balled end
can be used for AC welding of Al and Mg alloys
poor arc initiation and arc stability with AC compared with other
electrode types
used on less critical applications
low cost

Tungsten electrode types

Thoriated tungsten electrodes:
colour code - yellow/red/violet
20% higher current carrying capacity compared to pure tungsten
electrodes
longer life - greater resistance to contamination
thermionic - easy arc initiation, more stable arc
maintain a sharpened tip
recommended for DCEN, seldom used on AC (difficult to
maintain a balled tip)
This slightly radioactive

Tungsten electrode types

Ceriated tungsten electrodes:

colour code - grey (orange acc. AWS A-5.12)
operate successfully with AC or DC
Ce not radioactive - replacement for thoriated types

Tungsten electrode types

Lanthaniated tungsten electrodes:
colour code - black/gold/blue
operating characteristics similar with ceriated electrode

Tungsten electrode types

Zirconiated tungsten electrodes:
colour code - brown/white
operating characteristics fall between those of pure and
thoriated electrodes
retains a balled end during welding - good for AC welding
high resistance to contamination
preferred for radiographic quality welds

Choosing the proper electrode

Factors to be considered:
Electrode tip
not properly
heated

Unstable
arc

Too
low

Welding
current

Penetration

Too
high

Excessive
melting or
volatilisation

Tungsten
inclusions

Choosing the proper electrode

Current type influence

+ +

+
-

Current type & polarity

Heat balance
Penetration
Oxide cleaning action
Electrode capacity

DCEN

AC (balanced)

DCEP

70% at work
30% at electrode

50% at work
50% at electrode

35% at work
65% at electrode

Deep, narrow

Medium

Shallow, wide

No
Excellent
(e.g. 3,2 mm/400A)

Yes - every half cycle

Good
(e.g. 3,2 mm/225A)

Yes
Poor
(e.g. 6,4 mm/120A)

Shielding gas requirements

Preflow and
postflow

Shielding gas flow

Welding current

Preflow

Flow rate
too low

Postflow

Flow rate
too high

Special shielding methods

Torch trailing shield

Welding in protective tent

Special shielding methods

Pipe root run shielding

TIG torch set-up

Electrode extension

Stickout
Electrode
extension

Low electron
emission

Unstable arc

Too
small

2-3 times
electrode
diameter

Electrode
extension

Too
large

Overheating

Tungsten
inclusions

TIG - arc initiation methods

Arc initiation
method
Lift arc
simple method
tungsten electrode is in contact
with the workpiece!
high initial arc current due to
the short circuit
impractical to set arc length in
advance
electrode should tap the
workpiece - no scratch!
ineffective in case of AC
used when a high quality is not
essential

HF start
need a HF generator (sparkgap oscillator) that generates a
high voltage AC output (radio
frequency)
costly
reliable method
required on
both DC (for start) and AC (to
re-ignite the arc)
can be used remotely
HF produce interference
requires superior insulation

Types of current
DC

can be DCEN or DCEP

DCEN gives deep penetration

AC

can be sine or square wave

requires a HF current (continuos or
periodical)
provide cleaning action

Type of
welding
current
Pulsed
current

requires special power source

low frequency - up to 20 pulses/sec
(thermal pulsing)
better weld pool control
weld pool partially solidifies between
pulses

Current (A)

Pulsed current
Pulse Cycle Peak Background
time time current
current

usually peak current is 2-10

times background current
useful on metals sensitive to
high heat input
reduced distortions
in case of dissimilar
thicknesses equal penetration
can be achieved

Average current
Time

one set of variables can be used in all positions

used for bridging gaps in open root joints
require special power source

TIG welding parameters

welding current
penetration

arc voltage
weld width
travel speed
weld width + penetration
tilt angle

TIG Welding Variables

Voltage
The voltage of the TIG welding process is variable only by the type
of gas being used, and changes in the arc length

Current
The current is adjusted proportionally to the tungsten electrodes
diameter being used. The higher the current the deeper the
penetration and fusion

Polarity
The polarity used for steels is always DC ve as most of the heat is
concentrated at the +ve pole, this is required to keep the tungsten
electrode at the cool end of the arc. When welding aluminium and
its alloys AC current is used

TIG Welding Variables

Gas type and flow rate
Generally two types of gases are used in TIG welding, argon and
helium, though nitrogen may be considered for welding copper and
hydrogen may be added for the welding of austenitic stainless
steels.
The gas flow rate is also important.

Helium Argon mixes

Argon (Ar) Inert

Suitable for welding carbon
steel,stainless steel, aluminium
and magnesium

Suitable for welding carbon

steel, stainless steel,
copper, aluminium and
magnesium

Lower cost, lower flow rates

High cost, high flow rates

More suitable for thinner

materials and positional
welding

More suitable for thicker

materials and materials of
high thermal conductivity.

TIG Welding Variables

1.

2.

3.

4.

5.

1. Pre-flow timer control

Adjusts the time the gas and
water valves are open
2. Up-Slope control (Slope-In)
Prevents burn throughs and the
possibility of tungsten
inclusions
3. Output control
Welding current control

4. Down-Slope control (Slope-out)

Crater fill and controls crater
pipe and the possibility of crater
cracks
5. Post-flow timer control
Adjusts the time the gas flows
after welding

Checks With TIG Welding

The welding equipment
A visual check should be made to ensure the welding equipment is
in good condition
The torch head assembly
Check the diameter and specification of the tungsten electrode, the
required vertex angle and that a gas lens is fitted correctly. Check
the electrode stick-out length and that the ceramic is the correct
type and in good condition
Gas type and flow rate
Check the shielding gas is the correct type, or gas mixture and the
flow rate is correct for the given joint design, welding position as
stated in the WPS

Checks With TIG Welding

Current and polarity
Checks should be made to ensure that the type of current and
polarity are correctly set, and the range is within that given on the
procedure.
Other welding parameters
Checks should be made to other parameters such as torch angle,
arc gap distance and travel speed.
Safety
Check should be made on the current carrying capacity, or duty
cycle of the equipment and all electrical insulation is sound and in
place. Correct extraction systems should be in use to avoid
exposure to toxic fume.

Mechanised TIG

Cold wire
no current is flowing
through the wire
no
preheat
simple equipment
special wire feeders can
provide continuos,
intermittent or pulsed
feed
widely used on orbital
pipe welding and tubeto-tube sheet
applications

Mechanised TIG
Hot wire
current is flowing through the
wire
wire is resistance
heated nearly to its melting
temperature when it is in
contact with the weld pool
higher welding speed than
cold wire
high deposition rate

normally used in flat position
wire is usually fed into the
weld pool behind the arc

TIG typical defects

Most welding defects with TIG are caused by a lack of welder skill,
or incorrect setting of the equipment. i.e. current, torch
manipulation, welding speed, gas flow rate, etc.
Tungsten inclusions (low skill or wrong vertex angle)
Surface porosity (loss of gas shield mainly on site)
Crater pipes (bad weld finish technique i.e. slope out)
Oxidation of S/S weld bead, or root by poor gas cover
Root concavity (excess purge pressure in pipe)
Lack of penetration/fusion (widely on root runs)

Tungsten Inert Gas Welding

Advantages

Disadvantages

High quality

High skill factor required

Good control

Low deposition rate

All positions

Small consumable range

Lowest H2 process

High protection required

Minimal cleaning

Complex equipment

Autogenous welding

Low productivity

Can be automated

High ozone levels +HF

Any Questions

Tungsten Inert Gas Welding

Questions
QU 1. Give three reasons for the occurrence of tungsten
inclusions

QU 2. State the main welding parameters with the TIG welding

process

QU 3. Which electrode polarity is considered essential for the

welding of carbon steel? And give a brief description why

QU 4. Which electrode polarity is considered essential for the

welding of aluminium? And give a brief description why

QU 5. State the tungsten electrode activators required to weld

carbon steel and the light alloys

QU 6. State the main advantages and disadvantage of the TIG

welding process