Seminar Report

on

Tungsten inert gas welding

Session- 2015-16
By
Rahul Shaw (12/MM/27)
Department of Metallurgical and Materials Engineering
National Institute of Technology, Durgapur

Mentor: Dr. S. K. Mitra

Contents

Sl No.

Title

Page No.

1.

Certificate

2.

Introduction

3.

Welding Operation

2-4

4.

Types of Tungsten Electrodes

5.

TIG Shielding Gases

6.

Uses

7.

Advantages

8.

Disadvantages

9.

Applications

10.

References

10

Certificate
This is to certify that this report on Tungsten Inert Gas
Welding has been carried out by Rahul Shaw, final year
undergraduate student of the Department of Metallurgical and
Materials Engineering at NIT Durgapur under the supervision of
the undersigned.

Dr. S.K. Mitra

Professor
Department of Metallurgical and Materials Engineering
NIT Durgapur

1.

INTRODUCTION

Tungsten Inert Gas (TIG) 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 metal is
generally used. Also referred to as GTAW or Gas Shielded
Tungsten Welding.
A constant-current welding power supply produces electrical
energy, which is conducted across the arc through a column of
highly ionized gas and metal vapour known as a plasma. GTAW
is most commonly used to weld thin sections of stainless steel
and non-ferrous metals such as aluminium, magnesium, and
copper alloys. The process grants the operator greater control
over the weld than competing processes such as shielded metal
arc welding and gas metal arc welding, allowing for stronger,
higher quality welds. However, GTAW is comparatively more
complex and difficult to master, and furthermore, it is
significantly slower than most other welding techniques. A
related process, plasma arc welding, uses a slightly different
welding torch to create a more focused welding arc and as a
result is often automated.
GTA welding can be used to for nearly all types and thicknesses
of metal. GTA welding is flux less, slag less, and smokeless.
Welders have fine control of the welding process. GTA welding
is ideal for close-tolerance welds. Some GTA welds make the
critical root pass. GTA used when appearance is important.

2.

WELDING OPERATION

A. Manual Torch Movement

Torch and filler rod must be moved progressively and smoothly
so the weld pool, the hot filler rod end, and the solidifying weld
are not exposed to air that will contaminate the weld metal
area or heat affected zone.
When arc is turned off, postflow of shielding gas should shield
the weld pool, electrode, and hot end of the filler rod.

Fig 1: Torch movement

Fig

2: Torch
and

Filler
Metal
positioning

B. Torch Angle
As close to perpendicular as possible. May be angled 0-15
degrees from perpendicular for better visibility. As the gas flows
out it forms a protective zone around the weld. Too much tilt
distorts protective shielding gas zone. Velocity of shielding gas
affects protective zone. Low-pressure area develops behind the
cup when velocity increases. Sharper angle and higher flow
rate increases contamination.
C. Filler Rod Manipulation
Filler rod must be kept inside the protective zone. If filler rod is
removed from the gas protection, it oxidizes rapidly. Oxide is
added to the molten weld pool. When a weld is temporarily
stopped, the shielding gas must be kept flowing. If the rod tip
becomes oxidized, if should be cut off before restarting. The rod
should enter the shielding gas as close to the base metal as
possible. An angle less than 15 degrees prevents air from being
pulled in the welding zone.

Figure 3: The hot filler rod end is well within the protective gas
envelope.

Figure 4: Too much filler rod angle has caused oxides to be

formed on the filler rod end.

3. Types of Tungsten
Electrodes
Pure tungsten: Green
Pure Tungsten is an excellent non-consumable
electrode. Used for AC welding applications. It provide
good arc stability. Typically the least expensive, but is
more suitable to weld than thoriated and lanthanated.
Contains a minimum of 99.5% weight tungsten with no
other alloys. Most common metals used for include:
Aluminum and Magnesium Alloys (AC).
Pure tungsten can be improved by adding:
Cerium: 2% Ceriated Tungsten Orange
Used for AC or DC welding applications. An excellent
alternative to Thoriated tungsten especially in low
amperage welding. Takes approximately 10% less
current to initiate arc and has a very stable arc. Not a
radioactive material and tends to last longer than
thoriated. Contains 2% weight of Cerium Oxide (CeO2).
Most common metals used for include: Carbon and
Stainless Steels, Nickel Alloys and Titanium.
Thorium: 2% Thoriated Tungsten RED
Generally used for DC negative or
straight
polarity applications, this is the most
common
type of electrode used today.
Provides excellent resistance from
weld pool contamination, easier arc
starting capabilities and a more
stable arc. Contains 2% weight of
thorium oxide (ThO2). Most common
metals used for include: Carbon and
Stainless Steel, Nickel Alloys, and
Titanium.
Zirconium
Lanthanum

Fig5:
Tungsten Electrodes

4.

TIG Shielding Gases

1. Argon: It has good arc starting, good

cleaning action, good arc stability, focused
arc cone, lower arc voltages and 10-30 CFH
flow rates.
2. Helium: It gives faster travel speeds,
increased penetration, but difficult for arc
starting, less cleaning action, less low amp
stability, higher arc voltages, higher flow
rates (2x) and higher cost than argon.
3. Argon/Helium Mixtures: Improved travel
speeds
over
pure
argon,
improved
penetration over pure argon, cleaning,
properties closer to pure argon,improved arc
starting over pure helium, improved arc
stability over pure helium, arc cone shape
more focused than pure helium, arc voltages
between pure argon and pure helium, higher
flow rates than pure argon, costs higher than
pure argon.

Fig 6: Inert gas Cylinder

5. Uses
Gas tungsten arc welding is most commonly used to weld
stainless steel, mild steels and nonferrous materials, such
as aluminum and magnesium, but it can be applied to
nearly all metals.

Its applications involving carbon steels are limited not

because of process restrictions, but because of the
existence of more economical steel welding techniques,
such as gas metal arc welding and shielded metal arc
welding.

Aluminium and magnesium are most often welded using

alternating current, but the use of direct current is also
possible, depending on the properties desired.
For GTAW of carbon and stainless steels, the selection of a
filler material is important to prevent excessive porosity.
Oxides on the filler material and workpieces must be
removed before welding to prevent contamination, and
immediately prior to welding, alcohol or acetone should be
used to clean the surface.
Welding dissimilar metals often introduces new difficulties
to GTAW welding, because most materials do not easily
fuse to form a strong bond. However, welds of dissimilar
materials have numerous applications in manufacturing,
repair work, and the prevention of corrosion and oxidation.

6. Advantages
Welds more metals and metal alloys than any other
process
High quality and precision
Aesthetic weld beads
No sparks or spatter
No flux or slag
No smoke or fumes

7. Disadvantages
Lower filler metal deposition rates
Good hand-eye coordination a required skill
Brighter UV rays than other processes
Slower travel speeds than other processes

Equipment costs tend to be higher than other processes

8. Applications
While the aerospace industry is one
primary users of gas tungsten arc
welding, the process is used in a
number of other areas.

of

the

Many industries use TIG for welding

thin
workpieces,
especially
nonferrous metals.

It is used extensively in the

manufacture of space vehicles, and is
also frequently employed to weld
small-diameter, thin-wall tubing such
as those used in the bicycle industry.

In addition, TIG is often used in piping of

various sizes.

In maintenance and repair work, the

process is commonly used to repair
tools and dies, especially components
made of aluminium and magnesium.
Fig 7: TIG welded joints

10

REFERENCES
American Welding Society (2004). Welding handbook,
welding processes Part 1.
Jeffus, Larry (2002). Welding: Principles and
applications (Fifth ed.).
Minnick, William H. (1996). Gas tungsten arc welding
handbook.
Weman, Klas (2003). Welding processes handbook
https://en.wikipedia.org/wiki/Gas_tungsten_arc_welding