TIG Welding Process Guide

WELDING TECHNOLOGY
WELDING TECHNOLOGY
Gas tungsten arc welding
process
process
GAS TUNGSTEN ARC
WELDING
Istituto Italiano della saldatura
ENTE MORALE
2/42
TIG welding
The gas tungsten arc welding is an arc
welding process working with an arc
between a tungsten (nonconsumable)
electrode and the workpiece.
The area of the arc is enveloped in a
protective gas shield which protects the
fused zone and electrode from
contamination.
Filler metal may or may not be used.
The possible filler rod is added by hand; in
the mechanised process, the filler wire is
added by external feed rollers.
Different designations are used for the
process: T.I.G., G. T.A.W, ISO 4063 141
ENTE MORALE
3/42
TIG welding
Capacity of welding a big
range of thicknesses starting
from about 0,15 [mm]
Very good metallurgical
characteristics of the
welding seams
Wide field of
current regulation
Filler metal transfer
without loss of alloy
components
Advantages of T.I.G. process
ENTE MORALE
4/42
TIG welding
Stable and easily controllable
welding arc
Deformation reduction
Reduction of grain size increasing
Reduction of
heat affected zone
High ad concentrated
energy source
Welding seam very smooth
and regular
Advantages of T.I.G. process
ENTE MORALE
5/42
TIG welding
Difficult managing of
torch and filler metal
Low productivity rate
Low filler metal deposition rate
High skill level of welder
Disadvantages of T.I.G. process
Care should be taken to protect skin with
the proper clothing and protect eyes with the
correct shade lens in the welding hood
Brighter arc than SMAW and
GMAW process
ENTE MORALE
6/42
TIG welding
Thickness range for T.I.G. process:
The welding thicknesses range of T.I.G. changes The welding thicknesses range of T.I.G. changes
from 0,15 [mm] to 10 [mm]. The T.I.G. process is from 0,15 [mm] to 10 [mm]. The T.I.G. process is
particularly used for the first pass where isnt particularly used for the first pass where isnt
possible back gouge and back weld. possible back gouge and back weld.
For thicknesses higher than 5 [mm], after the first For thicknesses higher than 5 [mm], after the first
pass with T.I.G. process, it is better to use more pass with T.I.G. process, it is better to use more
productive processes like S.M.A.W. and G.M.A.W. productive processes like S.M.A.W. and G.M.A.W.
Some applications use Some applications use multipass multipass technique technique
T.I.G. process may be manual, fully mechanised,
automatic, robotized;
Typical automatic application are:
tubes to tube tubes to tube - - sheets welding sheets welding
orbital circumferential butt welds of tubes. orbital circumferential butt welds of tubes.
Application field of T.I.G process
ENTE MORALE
7/42
TIG welding
T.I.G. Welding equipment
The main components
of T.I.G. equipment are:
power supply and electric
circuit;
shielding gas system
with:
gas cylinder;
flowmeter and gas
saver;
gas circuit to the torch
cable carrier with:
electric circuit;
water cooling system
(when necessary)
gas circuit;
welding torch
section and control of welding parameters.
ENTE MORALE
8/42
TIG welding
Welding torch
Refractory
orifice
Torch plug
Tungsten electrode
ENTE MORALE
9/42
TIG welding
The most important elements of a
welding torch are:
1) a non consumable electrode of
tungsten or tungsten and
oxides;
2) gas nozzles;
3) torch plug;
4) gas lens;
5) torch cooling system;
The torch cooling system is constituted
by the shielding gas for welding torches
that are connected to current
generators till 200 [A]. For higher
power sources the torches are cooled
with a water cooling system.
Welding torch description
GAS LENS
ENTE MORALE
10/42
TIG welding
Polarity Direct current weldind
+
Torch
-
E
electrode
= 30% E
tot
E
work piece
= 70% E
tot
1)More stable arc
2)Greater penetration
3)Greater execution speed
++
Torch
-
E
electrode
= 30% E
tot
E
work piece
= 70% E
tot
1)More stable arc
2)Greater penetration
3)Greater execution speed
--
Torch
+
E
electrode
= 70% E
tot
E
work piece
= 30% E
tot
1)Greater electrode heating
2)Tungsten inclusion risks
3)Ionic blasting
4) Very low currents
ENTE MORALE
11/42
TIG welding
AC welding
Current Current
Arc voltage Arc voltage
OCV OCV
t t
1 1
t t
2 2
I I
1 1
I I
2 2
V V
2 2
V V
1 1
Current Current
Arc voltage Arc voltage
OCV OCV
t t
1 1
t t
2 2
I I
1 1
I I
2 2
V V
2 2
V V
1 1
Torch
E
electrode
= 50% E
tot
E
work-piece
= 50% E
tot
1) Use of higher currents than
DCEP
2)Lower ionic blasting than
DCEP
3) Arc less stable than DCEN
Torch
E
electrode
= 50% E
tot
E
work-piece
= 50% E
tot
1) Use of higher currents than
DCEP
2)Lower ionic blasting than
DCEP
3) Arc less stable than DCEN
AC welding is used when welding on
Aluminin an magnesium alloys, because of
the Ionic blasting and the low electrode
consumpion
Arc stability can be improoved by:
High frequency alternating current High frequency alternating current
Square wave current Square wave current
High frequency sparks High frequency sparks
ENTE MORALE
12/42
TIG welding
Pulsed current has some advantages in comparison
the standard T.I.G.:
1) Good penetration with less heat input
reduction of hot cracks;
2) Less distortion;
3) Good control of the pool when welding out of
position;
4) Ease of welding thin materials;
5) Ease of welding materials of dissimilar
thickness levels;
6) depth/width ratio till 2 to 1 in the welding of
stainless steels reduction of hot cracks;
7) sagging (seam concavity) reduction because
high currents and the short time of the pulsed
mode gives the possibility to the weld pool of
rapidly cooling;
8) small heat affected zone;
9) gas inclusions reduction because the pulsed
arc shakes the weld pool and permits the gas
discharge.
Pulsed current
ENTE MORALE
13/42
TIG welding
Pulsed current scheme
Peak Amperage: This value is usually set somewhat higher than it would be set for a non-
pulsed GTAW weld.
Background Amperage: This of course would be set lower than peak amperage.
Pulses Per Second Is the number of times per second that the weld current achieves peak
amperage.
% On Time Is the pulse peak duration as a percentage of total time. It controls how long
the peak amperage level is maintained before it drops to the background value.
Time [sec]

C
u
r
r
e
n
t

[
A
]
Arc
ignition
Welding
Arc
stop
Peak amperage
Background amperage
% On time
ENTE MORALE
14/42
TIG welding
Material
Aluminium (t 2.5 [mm])
Aluminium (t>2.5 [mm]) and aluminium alloys
Carbon steels and low alloyed steels
Stainless steels
Copper
Bronze
DC
EP
2
3
3
3
3
3
EN
2
2
1
1
1
1
Copper - aluminium alloys
3 2
Silicon-Bronze
3 1
Nickel and nickel alloys
3 1
Titanium
3 1
AC
1
1
3
3
3
2
1
3
2
2
Magnesium and magnesium alloys
2 3 1
Current choice: EN 26848
1 = Best results; 2 = Acceptable results; 3 = Not recommended
ENTE MORALE
15/42
TIG welding
Current intensity: EN 26848
ENTE MORALE
16/42
TIG welding
Electrodes codification (EN 26848)
The non consumable electrodes utilised for G.T.A.W. are composed by pure
tungsten (Wolframium) or tungsten with some added oxides.
The added oxides are: ThO
2
, ZrO
2
, LaO
2
, CeO
2
.
The added quantity is variable from 0,3% to 4%.
The non consumable electrodes are classified by an European Standard EN
26848 (Tungsten electrodes for inert gas shielded arc welding and for plasma
cutting and welding. Codification).
The electrodes are identified by the standard with the following codification:
EN 26848 W T 10
W is the first letter of the main element (Wolframium); T is the first letter of the
added oxide (in this case thorium); 10 is the average percentage of oxide content
divided 10.
Therefore: EN 26848 W T 10 means an tungsten electrode with 1% of thorium.
ENTE MORALE
17/42
TIG welding
EN 26848: electrodes code, composition and colour
Code
WP
WT4
WT10
WT20
WT30
WT40
Tungsten [%]
99,8
remainder
remainder
remainder
remainder
remainder
Composition
Impurities [%]
0,20
0,20
0,20
0,20
0,20
0,20
Oxides [%]
/
0,35 to 0,55 of ThO
2
0,80 to 1,20 of ThO
2
1,70 to 2,20 of ThO
2
2,80 to 3,20 of ThO
2
3,80 to 4,20 of ThO
2
WZ3 remainder 0,20
0,15 to 0,50 of ZrO
2
WZ8 remainder 0,20
0,70 to 0,90 of ZrO
2
WL10 remainder 0,20
0,90 to 1,20 of LaO
2
WC20 remainder 0,20
1,80 to 2,20 of CeO
2
Colour
Green
Blue
Yellow
Red
Violet
Orange
Brown
White
Black
Grey
ENTE MORALE
18/42
TIG welding
Electrodes codification (AWS 5.12)
The non consumable electrodes are also classified by an American Standard
AWS 5.12 as indicated below:
Code
EWP
EWCe-2
EWLa-1.5
EWLa-2
EWTh-1
EWTh-2
Tungsten [%]
99,5 min.
97,3 min.
97,8 min.
97,5 min.
98,3 min.
97,3 min.
Composition
Oxides type
/
CeO
2
LaO
2
LaO
2
ThO
2
ThO
2
Oxides [%]
/
1,80 to 2,20
1,30 to 1,70
1,50 to 2,00
0,80 to 1,20
1,70 to 2,20
Colour
Green
Orange
Gold
Blue
Yellow
Red
EWZr-1
EWG
98,3 min.
94,5 min.
ZrO
2
Rare earth
0,15 to 0,40
1,70 to 2,20
Brown
Grey
ENTE MORALE
19/42
TIG welding
Electrodes codification (AWS 5.12)
ENTE MORALE
20/42
TIG welding
Electrode currents (AWS 5.12)
ENTE MORALE
21/42
TIG welding
For DCEN use the tungsten electrode is tapered with a conical shape.
The cone edge shall be a needle point especially when are welded thin
sheets in the field between 0.12 [mm] and 1 [mm]. In this case the needle
point hasnt a great consumption because with DCEN the 70% of energy is
directed on the piece ad moreover the used current is very low. In other
applications, a slightly blunted end is preferred because the extreme point
may be melted off and end up in the deposit.
The height of the cone shall be in a field between 2 and 2.5 times of the
electrode diameter. Therefore, with an electrode of 1,6 [mm] the cone height
can pass from 3,2 [mm] to 4,0 [mm].
Electrode preparation (DCEN)
Electrode
2.5 electrode diameter
Tapered end
Needle point Blunted Balled end
ENTE MORALE
22/42
TIG welding
Electrode preparation
The grinding operations shall be executed in order to avoid concentric grinding
marks than can produce an unstable arc. If there are some grinding signs, they shall
run in the length direction of electrode. If the grinding is done on a coarse stone and
the grinding marks are concentric with the electrode, there are a series of ridges on
the surface of the ground area. There is a possibility of the small ridges melting off
and floating across the arc. If the stone used for grinding is not clean, contaminating
particles can be lodged in the grinding crevices and dislodge during welding, ending
up in the deposit.
1-stable arc
2-tapered end
3-grinding wheel
4-grinding marks
1-wandering arc
2-tapered end
3-grinding wheel
4-grinding marks
ENTE MORALE
23/42
TIG welding
Electrode visual appearance
ELECTRODE A has the ball end. This pure tungsten was used with
alternating current with a sine wave power source on aluminum. Notice the
end is uniform in shape and possesses a shiny bright appearance.
ELECTRODE B is a 2% thoriated tungsten ground to a taper and was
used with direct current electrode negative.
ENTE MORALE
24/42
TIG welding
Codification of consumables: EN 1668
ENTE MORALE
25/42
TIG welding
Codification of consumables: other standards
Other standards are:
EN 12070 ( Cr - Mo steels)
EN 12072 (Stainless steels)
ISO DIS 18273.2 (Aluminium and aluminium alloys)
The AWS standards are :
AWS 5.18 (Carbon steels)
AWS 5.28 (Low alloy steels)
AWS 5.9 (Stainless steels)
AWS 5.10 (Aluminium and aluminium alloys)
AWS 5.14 (Nickel and nickel alloys)
ENTE MORALE
26/42
TIG welding
Shiedling Gases : Argon
Argon has low thermal conductivity which means it is not a good conductor of
heat. This results in a more compact, higher density arc. The core part of the
arc is more hot in comparison with helium and for this reason the weld metal
drops that pass in the arc zone are more fluid.
Arc density refers to the concentration of energy in the arc. With argon this
energy is confined to a narrow or more pinpointed area and then also the
penetration is deep ad narrow.
N
EN 1089-3
Gas cylinder colour
Old colour
lilac
New colour
Green
ENTE MORALE
27/42
TIG welding
Shieding gases: Helium
Helium is present in the atmosphere in quantity of 5 parts for one million.
In the United States and in Canada there are natural sources where Helium is
produced with an high grade of purity.
Helium used for welding has a gas purity grade greater than 99,995 [%].
Unlike argon, helium has high thermal conductivity. Due to this higher thermal
conductivity, the arc column expands, reducing current density in the arc. The
arc column will become wider and more flared out than the arc column with
argon shielding gas. The consequence is a wider penetration in comparison
with Argon shielding gas and less risks of undercuts on the boundary of the
welding seam.
Greater are also the penetration and the dilution.
Wider and deeper penetration
with Helium
N
EN 1089-3
Gas cylinder colour
Old colour
Brown
New colour
Brown
ENTE MORALE
28/42
TIG welding
Argon-Helium mixtures
Mixtures are used in order to have intermediate characteristics between argon
and helium,
These mixtures have:
1) more arc stability compared with pure helium;
2) more penetration compared with pure argon;
3) greater welding speed compared with pure argon.
The most often used mixtures are:25 [%] Ar-75 [%] He
30 [%] Ar-70 [%] He
ENTE MORALE
29/42
TIG welding
Argon-Hydrogen mixtures
Just as helium is mixed with argon to take advantage of the best features of
both gases, hydrogen is mixed with argon to further constrict the arc and
produce a cleaner weld with a greater depth to width ratio (penetration).
This mix is used primarily for welding austenitic stainless steels and some
nickel alloys. The addition of hydrogen to argon also increases travel speed.
It should be noted that an argon hydrogen mix will introduce the risk of
hydrogen cracking, undercuts and metal porosity particularly in multipass
welds.
This type of mixture, in the most used quantities, (95 [%] of Ar and 5 [%] of H
2
)
is not inert, but slightly reducing.
N
EN 1089-3 Gas cylinder colour of Hydrogen
Old colour
Red
New colour
Red
ENTE MORALE
30/42
TIG welding
Backing shielding
Just as the surface of the weld bead must be protected from atmospheric
contamination, the backside must be protected as well. In the case of pipe
welding or other full penetration butt joints, this can be accomplished with a
backing dam, as seen in the following picture.
Often a backing dam can be something as simple as heavy paper used to
close off the ends of the pipe through which a gas hose is passed to fill the pipe
with shielding gas.
In some cases where the weld occurs too fast for the torch supplied shielding
gas to protect the pool and tungsten, a trailing shield may be used. Trailing
shields are available as separate devices that attach to the torch or torch
nozzle. Back or trail shielding is required on reactive metals like titanium,duplex
steels, stainless steels, etc. This type shielding keeps
the welds bright and shiny without discoloration and oxidation, thus reducing
rework due to contamination.
ENTE MORALE
31/42
TIG welding
Backing shielding
The absence of a backing gas is not so relevant if the material to be welded is:
1) thick;
2) carbon steel;
3) not necessary a smooth shape of backing welding seam;
4) not subjected to an corrosive environment.
On the contrary, for tubes with small thicknesses and metals with chromium
2 [%] or stainless steels, titanium, tantalum,zirconium is necessary, for the first
pass and normally also for the second pass, an efficient gas backing.
The gas backing may be the same of the gas shielding or different. For
alloyed steels good results are obtained also with Nitrogen-hydrogen, pure
nitrogen gases.
For backing shielding is important that gas flow for a small period of time
before welding in order to eliminate the air; particularly for tubes is necessary a
gas flow in volume that is ten times the backing room of the tube. The gas
pressure shall be slightly above the ambient pressure in order to avoid air
infiltration, but not so high to produce, during a circumferential weld execution,
a root concavity defect.
ENTE MORALE
32/42
TIG welding
Supplementary shielding gas
In titanium welding may be used a supplementary gas shielding system
(trailer gas) with a cable, on the torch that permits, with a porous mass the
shielding of the seam already solidified.
Argon Argon
Argon to torch Argon to torch
Porous Porous
material material
Welding Welding
Torch direction Torch direction
ENTE MORALE
33/42
TIG welding
In the TIG process are necessary some precautions:
The process hasnt slag; therefore, is necessary a very good cleaning
action of the welding bevels in order to decrease the hot crack risk;
during the arc ignition is necessary avoid the contamination of the
welding pool by the tip of the torch. ;
The best position of the torch and filler metal is shown in the following
picture:
Piece Piece
Torch Torch
75 75
15 15
Filler metal Filler metal
Torch direction Torch direction
Operation technique
ENTE MORALE
34/42
TIG welding
Special applications
TIG process is used in automatic applications: for example in the tube to tube-sheet
welding and in the butt circumferential welds of pipes.
Tube Tube- -sheet sheet
Tube Tube
TIG torch TIG torch
Different welding edge preparation Different welding edge preparation
of tube to tube of tube to tube- -sheet welding sheet welding
TIG torch TIG torch
Tube Tube- -sheet sheet
Tube Tube
ENTE MORALE
35/42
TIG welding
Special applications (tube to tube-sheet welding)
Coffee processing plant, AISI 304L steel Coffee processing plant, AISI 304L steel
Cu Cu- -Ni Ni tubesheet tubesheet for the salt industry for the salt industry
ENTE MORALE
36/42
TIG welding
Orbital welding
Circumferential Circumferential
weld weld
TIG torch TIG torch
Tube Tube
ENTE MORALE
37/42
TIG welding
Hot wire TIG
The main difference, in comparison with
standard TIG, is the wire filler metal pre-
heating with a supplementary power
source.
The electric arc works with lower heat
inputs
The welded materials are the same of the
standard TIG: carbon and low alloyed
steels, stainless steels (duplex and
superduplex), nickel and titanium
alloys.
The process is particularly used for
welding of tubes with medium-high
thickness
Up from 15 [mm] of thickness is the
narrow gap (NG) preparation is used, with
an increase of productivity up to 300%.
ENTE MORALE
38/42
TIG welding
Key hole TIG
Is a variation of TIG cold wire process that permits:
- more simple edges preparations (also square bevels)
- reduction or elimination of filler metal
-higher productivity.
In the example a comparison between standard TIG and key hole TIG
welding of 12 [mm] thickness in AISI 304L
ENTE MORALE
39/42
TIG welding
Key hole TIG
The key hole TIG is applied
with a pass through technology
on the welded thickness
In comparison with standard
TIG is improved the weldability
of material with low thermal
conductivity (stainless steels
and titanium alloys)
The welding position is flat
One big advantage is the
elimination of the Marangoni
effect.
Marangoni Effect is the result of
some added chemical elements on
the surface tension of the weld pool
that decreases the penetration (for
example in duplex steels).
Small addition of SO
2
(till 600 ppm)
can reduce or eliminate the
problem.
ENTE MORALE
40/42
TIG welding
Typical imperfections of TIG welding
Tungsten inclusions
isolated (with a polyhedral regular shape);
Cluster (spray): have bi-dimensional shape with sharpened edges
and are possible starts of cracks ;
oxidations: is possible on the backing of the seam during welding
of Cr-Mo steels (Cr > 2 [%]) if isnt foreseen the gas backing
shielding;
Gas inclusions (porosity and gas cavities). Some causes are:
not carefully cleaning of welding bevels;
poor operation technique (in the torch and filler metal movement);
contamination of shielding gas from the cooling circuit of the torch.

TIG Welding Process Guide

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