A

SUMMER INTERNSHIP REPORT

ON
DESIGNING A FEED MECHANISM FOR TUNGSTEN
INERT GAS WELDING
Under the Supervision of
Dr. Name

Submitted by

Submitted to

Name
Roll No.
M.tech.( Production Engg.)

Prof. Name

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY
ROURKELA
Abstract

Tungsten inert gas welding (TIG) or gas tungsten arc welding (GTAW) is an inert-gas
shielded arc welding process using a non consumable tungsten electrode. TIG is used for joining
of a number of materials though the most common are Al, Mg, and stainless steel. It is applicable
for thin sheet welding but by using filler metal it can be used for thick sheet welding. The
feeding of filler metal can be done manually or by some automated mechanism. Designing an
automated feeding mechanism and fixing the torch on some automated guided vehicle will
convert the welding system into constant voltage type and will serve a lot of application which
require less human handling.
First mentions of the use of fluxes during the TIG processing were made with reference
to titanium alloy welding. A little later, the activating flux was satisfactorily used in the welding
of high-strength steels. In the 1960s of the last century these were widely used in the armaments
and aircraft industries.

1. Introduction

Gas tungsten arc welding (GTAW) also known as tungsten inert gas (TIG) welding, is an
arc welding process that uses a non-consumable tungsten electrode to produce the weld. The
weld area is protected from atmospheric contamination by an inert shielding gas (argon or
helium), and a filler is normally used, though some welds, known as autogenous welds, do not
require it. A constant current welding power supply produces energy which is conducted across
the arc through a column of highly ionized gas and metal vapors known as plasma.
Heat input in GTAW does not depend on the filler material rate. Consequently, the
process allows a precise control of heat addiction and the production of superior quality welds,
with low distortion and free of spatter. It is less economical than other consumable electrode arc
welding processes, due to its lower deposition rate, and it is sensitive to windy environment
because of the difficulty in shielding the weld pool. Besides it shows low tolerance to
contaminants on filler or base metals.
Due to its low density, excellent high temperature mechanical properties and good
corrosive resistance Ti-6Al-4V alloy has been widely used in the aerospace, automotive,
petrochemical and nuclear power plant industries. Tungsten inert gas welding is one of the most
widely used welding methods for titanium alloy.
Chemical composition of Ti-6Al-4V alloy
Elements
% by weight

Al
6.3

V
4

C
0.006

Fe
0.17

O
0.166

Mechanical properties of Ti-6Al-4V alloy

Ultimate tensile strength
Notch tensile strength
Yield strength
Elongation
Vicker's hardness (0.5kg)
charpy impact test

1.1 TIG welding equipment

The TIG welding equipment chiefly consist of

998 Mpa
1146 Mpa
910 Mpa
10 %
320
18 J

N
0.006

H
0.002

Ti
Balance

A TIG Torch a tool to control the arc.

A power source which is capable of providing the necessary welding current.
A TIG unit with incorporated control system that make it possible to adjust the welding
current arc initiation etc.
A shielding gas cylinder with pressure reducing valve & flow meter.

1. Cable for welding current

2. Cable for welding current
3. Control cable for TIG unit
4. Shielding gas
5. Cable for welding cable for TIG torch
6. Control cable for TIG torch
7. Welding cable with positive polarity

2. Literature Review
Gao et al. (2012) have done comparison between Nd:YAG laser and tungsten inert gas welding
on Ti-6A-4V titanium alloy joints. They compared characteristics such as residual distortions,

weld geometry, microstructure and mechanical properties of the joints with LBW and TIG
welding. Finally they conclude the result that welded joint by LBW has the characters of small
overall residual distortion, fine microstructure, narrow heat-affected zone (HAZ) and high
Vickers hardness over the TIG process. LBW welding method can produce joints with higher
strength and ductility
Babu et al. (2006) performed the influence of direct current pulsing on the microstructure,
hardness at room temperature and tensile strength at different temperatures of tungsten inert gas
(TIG) welding process in Ti6Al4V alloy. Under in these experiments they conclude the result
that both pulsed and unpulsed weldments when subjected to the post-weld heat treatment
(PWHT) at 900 C resulted in improvement in ductility and reduction in strength of weldment
and PWHT exhibited almost the same values of strength and ductility. Pulsing of the welding
current resulted in some grain refinement in TIG welds of Ti6Al4V. The reduction in prior
grain size improved hardness, strength and ductility of the pulsed current weldments in the as
welded condition.
Balasubramanian et al. (2006) performed a single pass gas tungsten arc welding of Ti-6Al-4V
alloy. They used pulse current during these experiments. Hence they develop mathematical
model to predict tensile properties of pulse current gas tungsten arc welding. They discussed
mainly four parameter peak current, background current, pulse frequency & pulse on time in
certain range to determine the mathematical models. The adequacy of the models has been
checked by ANOVA technique. By using the developed mathematical models, they get the final
result that the tensile properties of the joints can be predicted with 99% confidence level.
Balasubramanian et al. (2007) have done investigation on corrosion behavior of Ti-6Al-4V
alloy by using pulsed current gas tungsten arc welding. They used the predominated parameter
under in these experiments are welding current, pulse frequency and pulse on time. The max &
min value of corrosive rate during the experiment was 3.18 & 0.51 mils/yr respectively. This
investigation revealed that up to an optimum value corrosive resistance of joints increase with
increasing current and pulse frequency. Beyond the optimum value the corrosive resistance will
decrease. During fabrication process there would be reduction in corrosive resistance if grain
growth is a coarse grain material.
Shixiong et al. (2013) investigate that the addition of Zr & Cu enhanced the spreadability of Al
based filler on Ti-6Al-4V alloy in tungsten inert gas welding process. They found that the joint
with Al-Cu-Zr filler has higher tensile property. They used welding parameters 120 A current and
75 mm/min welding speed. The whole experiment was conducted using a Panasonic YC500WX4 welding machine. Additions of Cu and Zr allowed better spreading of the filler on
surface mainly depend on the heat input in the welding process. The influence of Zr addition on
interfacial layer varied with heat input. The layer with low heat input exhibited discontinuous
morphology.

Larey et al. (2010) performed microstructural & microtextural analysis to show that the
technique has the potential high integrity welds in Ti-6Al-4V alloy. In this analysis they used gas
tungsten constricted arc welding (GTCAW) process. GTCAW referred to as the interpulse
technique. Basically GTCAW is a particular modification of conventional gas tungsten arc
welding process. This technique can reduce the heat input during gas tungsten constricted are
welding compared to the conventional gas tungsten arc welding process. Micro textural analysis
related to the cooling rate associated with the welding process.
Esmaily et al. (2012) done experiments by using gas tungsten arc welding & friction stir
welding process of Ti-6Al-4V alloy. They obtain microstructure of Ti-6Al-4V alloy after
completion of these two welding experiments. Basically difference between these two process is
that the the varying welding parameter are welding current and rotational speed in case of GTAW
& FSW process respectively. The samples welded by using GTAW process are subjected to
various current between 90 and 120 A. In FSW process samples were welded by different
rotational speeds (450850 rpm). Finally they conclude the result that the microstructures of
sample welded by GTAW processing were finer in size when subjected to 100 A. If the rotational
speed about 650 rpm in FSW process also microstructures of sample were finer in size.
Yong et al. (2013) performed an experiment by using ultra high frequency pulse gas tungsten arc
welding (UHF-GTAW) of Ti-6Al-4V alloy. In this experimental program they describe the
characteristics such as mechanical properties, microstructure and the defection of the welds. The
UHF-GTAW process done with a high frequency of 10-50 kHz. The experimental analysis show
that the high frequency reduces the heat input from the UHF-GTAW process. Finally they
conclude that compared with the conventional GTAW process heat input decreased in UHFGTAW process. Effect of pulse frequency and heat input also reduce the grain size & mechanical
properties of welds.
Balasubramanian et al. (2010) have done an experimental program to compare the fatigue
performance of Ti-6Al-4V alloy fabricated by gas tungsten arc welding (GTAW), laser beam
welding (LBW) and electron beam welding (EBM) processes. Fatigue failure is one of the prime
concerns in structural design. It was noted under this experiment that significant increase in
fatigue crack growth resistance due to the presence of tensile residual stress. From the
investigation important conclusion are of the three joints that, the joint fabricated by GTAW
process exhibited low fatigue strength and high sensitivity compared to the LBW and EBM.

3. Principle of TIG welding

3.1 Process description

Tungsten inert gas (TIG) welding is a process that produces an electric arc maintained
between a non consumable tungsten electrode and the part to be welded. The heat-affected zone,
the molten metal, and the tungsten electrode are all shielded from atmospheric contamination by
a blanket of inert gas fed through the GTAW torch. Inert gas (usually Argon) is inactive or
deficient in active chemical properties. The shielding gas serves to blanket the weld and exclude
the active properties in the surrounding air. Inert gases, such as Argon and Helium, do not
chemically react or combine with other gases. They pose no odor and are transparent, permitting
the welder maximum visibility of the arc. In some instances Hydrogen gas may be added to
enhance travel speeds.
The GTAW process can produce temperatures of up to 35,000 F (19,426 C). The torch
contributes heat only to the work piece. If filler metal is required to make the weld, it may be
added manually in the same manner as it is added in the oxyacetylene welding process, or in
other situations may be added using a cold wire feeder. GTAW is used to weld steel, stainless
steel, nickel alloys such as Monel and Inconel, titanium, aluminum, magnesium, copper, brass,
bronze, and even gold. GTAW can also weld dissimilar metals to one another such as copper to
brass and stainless steel to mild steel.
3.2 Selecting a power source
Choice of a TIG power source is driven by the type and thickness of the material you will
weld. This will determine whether you require a machine for all weldable metals except
Aluminum and Magnesium (DC) or one that is for all weldable metals (AC/DC).
Items to consider
Type of metal to be welded - (Aluminum, Steel, Stainless, etc.).
Thickness of materials to be welded.
Package solution that suits the welding application.
Accessory components that add performance to the system.
Physical Machine Size Inverter/TransformerRectifier

Fig.1 Principle of TIG welding

4. Working procedure of TIG

A movable vehicle used to hold the TIG torch. The indispensable of all is screw and nut
which aided in setting up a feasible and comprehensive mechanism. This type of welding will be
characterized as constant voltage type because the distance between the work piece and the torch
tip will remain constant throughout the course of welding.

Fig.2 Experimental set up of TIG

The speed of the Vehicle is controllable and can be varied according to the requirement of
the welding speed, amount of heat required and the amount and rate of deposition. The torch tip
and the filler metal are to be aligned at a very precise angle so that proper heating of filler metal
takes place and simultaneously we get a proper rate of deposition with uniform bead size. The
linear downward movement of the filler metal is controlled by the screw nut mechanism. By
rotating the screw we can vary the speed of deposition of filler metal. Also while doing the
constant voltage type of welding like TIG care should be taken to the work piece flat and
clamped so that it doesnt move while welding. Now taking into consideration the speed of
welding and thickness of metal work piece (which is to be welded) objective of the present work
is to synchronize the feeding of filler metal with the speed of Vehicle and for that a suitable
mechanism is required to accomplish the task.

5. Application of TIG Welding

5.1 Areas of application

Tungsten inert gas welding process is often used for jobs that demand high quality welding such
as for instance
The offshore industry
Combined heat and power plants
The petrochemical industry
The food industry
The chemical industry
The nuclear industry
5.2 Advantages of GTAW welding process
Concentrated Arc - Permits pinpoint control of heat input to the workpiece resulting in a
narrow heat-affected zone.
No Slag - No requirement for flux with this process; therefore no slag to obscure the
welders vision of the molten weld pool.
No Sparks or Spatter - No transfer of metal across the arc. No molten globules of spatter
to contend with and no sparks produced if material being welded is free of contaminants.
Little Smoke or Fumes - Compared to other arc-welding processes like stick or flux cored
welding, few fumes are produced. However, the base metals being welded may contain
coatings or elements such as lead, zinc, copper, and nickel that may produce hazardous
fumes. Keep your head and helmet out of any fumes rising off the work piece be sure that
proper ventilation is supplied, especially in a confined space.
Welds more metals and metal alloys than any other arc welding process.
Good for welding thin material.
Good for welding dissimilar metals together
5.3 Disadvantages of GTAW welding process
Slower travel speeds than other processes.
Lower filler metal deposition rates.
Hand-eye coordination is a required skill.
Brighter UV rays than other processes.
Equipment costs can be higher than with other processes.

6. Electrical safety

Do not touch live electrical parts.

Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats or covers big enough to
prevent any physical contact with the work or ground.
Do not use AC output in damp areas, if movement is confined, or if there is a danger of
falling.

Use AC output ONLY if required for the welding process.

If AC output is required, use remote output control if present on unit.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the arc to remove
welding fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator

7. Conclusion

Thus by the above mentioned methods we are able to make a Partial or fully mechanised
TIG welding setup. This will serve as constant voltage type welding machine.
Also by further synchronizing it with an electric motor the mechanism will be a fully
automated and will require no human involvement throughout the course of welding.
It will be very helpful for constant voltage type welding and will be implemented in
various industrial and as well as non industrial.

References
1. Xiao - Long Gao, Lin - Jie Zhang , Jing Liu & Jian - Xun Zhang (2012), Comparative
study of pulsed ND:YAG laser titanium alloy plate a journal of of material science &
engineering vol. 559, pp 14-21.
2. N. Kishore Babu, S. Ganesh Sundara Raman, R. Mythili , S. Saroja (2006), Correlation
of microstructure with mechanical property TIG weldment of Ti-6Al-4V made with
weldment current, journal of material characterization vol. 58, pp 581-587.
3. M. Balasubramanian, V. Jayabalan, V. Balasubramanian (2006), Developing
mathematical models to predict tensile property of pulsed current GTAW welding on
alloy, journal of material science & design vol. 29, pp 92-97.
4. M. Balasubramanian, V. Jayabalan, V. Balasubramanian (2007), Effect of pulsed GTAW
on corrosive behavior of Ti-6Al-4V alloy, journal of material science & design vol. 29, pp
1359-1363.

5. Shixiong Lv, Qinglong Cui, Yongxian Huang & Xiaojun Jing (2013), Influence of Zr
addition on TIG welding brazing of Ti-6Al-4V to A5A06 alloy, journal of material
science & engineering A vol. 568, pp 150-154.
6. Rowan K. Leary, Eleanor Merson, Keith Birmingham, David Harvey & Rik Brydson
(2010), micro structural & micro textural analysis of inter pulse GTCAW welds in Cp-Ti
& Ti-6Al-4V alloy, journal of material science & engineering A vol. 527, pp 7694-7705.
7. M. Esmaily, S. Nooshin Mortazavi, P. Todehfalah, M. Rashidi (2012), Micro structural
characterization in Ti-6Al-4V formation of martensite phase in alloy butt joints
produced by friction stirr welding & GTAW process journal of material science & design
vol. 47, pp 143-150.
8. Mingxuan Yang & Bojin Qi & Baoqiang Cong & Fangjun Liu & Zhou Yang (2013),
Effect of pulse frequency on microstructure & property of Ti-6Al-4V alloy by ultra sonic
frequency Pulse gas tungsten inert gas welding, a journal of advance manufacturing
technology vol. 68, pp 19-31.
9. T.S. Balasubramanian, V. Balasubramanian, and M.A. Muthumanikkam (2010), Fatigue
performance of gas tungsten welding, Electron beam welding & Laser beam welding by
Ti-6Al-4V alloy joint, a journal of material science and performance vol. 20, pp 1620
1630.