Technical Definition & Description of

TIG Welding
Introduction:
Welding is a fusion process in which two metal surfaces are heated and
joined together. The process is used heavily across dozens of industrial and
manufacturing fields. There are several different methods of producing a
weld. Gas tungsten arc welding (GTAW) also known as Tungsten Inert Gas
(TIG) welding is a type of welding that uses a non-consumable tungsten
electrode to heat the weld zone.
Developed in the 1930s and still widely popular today, TIG welding is one of
the most common welding
methods for materials such as
stainless steel and aluminum.
The method is also used for
materials including copper,
titanium and magnesium. TIG
welding is typically a manual
process, requiring one hand to
provide filler metal to the weld
pool and another hand to hold
the torch. A foot pedal is used to
adjust voltage (heat of the weld
pool) during the weld. TIG
welding also requires a shielding
gas to protect the welding arc
from atmospheric gases that can
harm the final product.

Standard Equipment:
TIG welders are compromised of 4 Figure 1: Operator TIG welding
primary components. The 4 http://www.welderbros.com/best-tig-welder-
reviews
components are a power source, a
welding torch, tungsten electrode, and shielding gas supply. Figure 2 below
demonstrates a common TIG welding setup.
Welding Torch:
Figure 2: TIG welding setup
The welding torch http://nptel.ac.in/courses/112107144/welding/lectu
controls the welding arc and forms the weld pool. Once
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initiated, a water or air system cools the
torch from overheating. Water-cooled
systems are generally required for
welding thicker materials (requiring
higher currents) where as air-cooled are
suitable for thinner materials. Externally,
the torch is composed of thermal
insulators to contain heat and electrical
current. Internally, the torches consist of a
copper lining, which is very helpful for
transmitting heat to the weld zone.
Additionally, the tungsten electrode as
well as shielding gas lines are incorporated into the torch head.

Tungsten Electrode: Figure 3. TIG welding torch

https://www.arc-
A tungsten electrode serves as a zone.com/blog/carmenelectrode/wp-
conductor to provide current (and thus content/weldcraft-wp-18-torch.jpg
heat) to form the welding arc. Tungsten is used because of its extremely high
melting temperature. Thus the electrode can get hot enough to melt steel or
aluminum without receiving internal damage. Tungsten electrodes come in
either balled or pointed tips. Balled tips are typically used for welding
aluminum where as pointed tips are used for steel. Aside from pure tungsten,
electrodes can also come in four different types of tungsten alloys. Varied
alloys can have benefits such as enhanced arc stability when welding
materials such as copper or magnesium.

Power Source
The power source provides a constant current to heat the torch. Because TIG
welding is a manual process, small distance fluctuations from the work piece
are not uncommon. The constant current allows for uniform heat across the
weld pool regardless of fluctuations in arc distance. The power source can
provide either direct or alternating current depending on the material being
welded. Direct current is commonly used to weld steel, while alternating
current is used to weld aluminum. A high frequency electric spurt from the
power source initiates the welding arc. This is called a high frequency start.
The power source also incorporates a pre and post flow feature. The two
features help guide effective shield gas release.

Shielding Gas:
TIG welders include an attached shielding gas canister. The gas, typically
argon, effectively blocks contaminating atmospheric gases. Without a
shielding gas, atmospheric gases such as oxygen and nitrogen can get
trapped in the weld resulting in defects. These defects can damage the
strength and integrity of the finished product. Just prior to arc initiation (pre
flow), the shielding gas exits the torch surrounding and protecting the
intended welding zone. Gas continues to release and shield the weld zone
after arc initiation. A ceramic cup extending from the tip of the welding torch
helps to guide the gas around the arc. Ceramic is used because it is
exceptionally resistant to heat. When the welding arc is shut down, the
shielding gas continues to flow (post flow), protecting the weld as it cools
and solidifies.

Accessory Equipment:
Often times TIG welders are upgraded to provide more features. Pulsed
current as well as wire feeders are two common accessory features for TIG
welders.

Pulsed Current
The TIG power source can include
upgraded control boards that deliver
helpful features. For example, a
pulsed current upgrade is a common
upgrade that allows the torch to heat
the weld zone in timed spurts. This
lets the weld zone harden prior to
reheating. Pulsed current results in a
more controlled weld zone and a
better quality weld. Figure 4 to the
right shows a pulsed current weld. Figure 4. Pulsed current weld
Each ridge indicates a single heat https://www.pinterest.com/explore/tig-welding-
pulse. aluminum/

Wire Feeder
Wire feeders automatically add filler wire to the weld pool allowing for a
more controlled feed wire delivery. Welding operators who have difficulty
keeping a steady hand while feeding filler wire typically use wire feeders.
Wire feeders are also a very useful application for automated TIG welding.
For instance, metal 3D printers, which occasionally incorporate TIG welders,
use a wire feed to provide a controlled metal delivery to the welding pool.
Safety:
To protect the welding operator and bystanders, common safety features are
utilized during TIG welding. Thermal jackets and gloves protect the welding
operator from intense heat and ultraviolet light during welding. Additionally,
welding helmets are worn to protect the operator from heat and stray sparks.
All helmets have shaded lenses to shield the operators eyes from ultraviolet
rays. Modern helmets include auto darkening mechanisms that automatically
dim when exposed to bright light. Ultraviolet light resistant plastic curtains
are used to surround the area where welding is taking place. The curtains are
used to protect bystanders near a welding operation.

Conclusion:
TIG welding is a very common type of welding process. The torch, power
source, tungsten electrode, and shielding gas work together to produce a
weld. TIG welding can be even further enhanced with additional features
such as pulsed current or wire feeding. As long as the operator practices
proper safety methods, TIG welding can be one of the most effective modern
welding methods.