TIG - Direct-Current Welding with High-Frequency Pulses, an Interesting

Process Variant

D. Dzelnitzki, Muendersbach

Welding current I [A]

1 Introduction

Tungsten-inert-gas welding (TIG) is one of the most

important joining technologies in welding-related fabri-
cation. High-quality weld joints without spattering and

IP
slags qualify this welding technology for the major part

Im
of metals. As the filler-metal supply is separated from

IG
the arc, the molten pool can be controlled in the best tG tP
way possible - an advantage which ensures the quality Time t [s]
of the execution of the weld but entails a relatively low
1 pulse cycle = 1/f
deposition rate and welding speed. If the welding
speed is increased, the arc looses some of its stability IG = basic current f = pulse frequency
and the penetration decreases. Above a critical value, Im = medium amperage tG = basic time
depending on the welding parameters selected, no IP = pulse current tP = pulse time
continuous weld can be achieved any more [1]. tP x 100%
On the basis of these experiences, several TIG pulse duty ratio T =
(tG+tP)
torches are combined (multi-cathode torch), or TIG
Fig. 1. TIG - Pulsed-arc welding, terms
dual-flow torches as well as plasma torches are used
in order to increase the welding speed in automatic A pulse frequency of 0.5 - 6 Hz should be selected,
fabrication processes. The high requirements in torch because higher values practically do not result in a
construction and torch operation turn out to be a dis- temperature difference between pulse and basic level
advantage in this respect. and thus produce a temperature course similar to non-
With laser welding devices, a considerable increase in pulsed TIG welding. In this respect, 40 - 60 % is con-
the welding speed can be achieved. However, the high sidered to be a sensible pulse duty ratio [2].
costs and the extremely low efficiency often hinder the Under these circumstances, we have to face the
employment of these devices. question: What is the use of TIG direct-current welding
TIG direct-current welding with high-frequency pulses with high-frequency pulses?
also leads to a considerable increase in the welding The arc provides the answer. By heterodyning with a
speed. In ranges of material thicknesses up to about 2 frequency of a few Hertz to 35 kHz, its shape can be
mm, this welding method thus represents an interest- influenced. The arc column is contracted and as-
ing low-cost alternative to multi-cathode and laser sumes a cylindrical shape [3]. In consequence, the arc
welding. pressure rises, fig. 2.
2 Characteristics of high-frequency TIG pulsed-
arc welding
2.1 Process principle

TIG welding with pulsating current has been known for

many years. It is mostly used for fully-mechanised and
automatic welding processes. The welding current
Arc pressure TN

weaves periodically between a high (pulse current Ip)

and a low (basic current IG) value. In the basic-current
phase, the low temperature causes a decrease in the
volume of the molten pool. Thus, the heat input is
reduced and optimum control of the molten bath is
ensured. Of course, the pulse parameters (pulse cur-
rent Ip , basic current IG, pulse frequency f and the
pulse duty ratio T), fig. 1, must be adjusted precisely to Pulse frequency f
the respective application in order to guarantee the
desired difference of the temperature between high- Fig. 2. Arc pressure as a function of the pulse frequency [3],
tungsten electrode: 2,4 mm, 2% thoriated, sharpening
current and low-current phase. According to [2], the
angle of the electrode: 60,
ratio between pulse and basic current (Ip /IG ) should medium amperage: 50 A, current amplitude: 150 A,
be 1.25 - 4. basic current: 5 A, arc length: 2 mm

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penetration TN Arc length lLB

10 kHz

0 Hz
Pulse current IP
Fig. 3. Change of the penetration in TIG welding with pulse
heterodyning of the welding current [3]
1 TN = f (IP), 2 TN = f (LB) 10 kHz, 3 PN = f (LB) 0 Hz Fig. 4b. Arc formation of non-pulsed TIG- welding [4],
IS = 292 A, vS = 2,0 m/min,
While, up to a frequency of about 5 kHz, this effect is shielding gas: 95% Ar + 5% H2
very strong, further frequency increases do only cause
minimal arc-pressure increases. Besides the pulse 2.2 Power sources and equipment
frequency, a growing pulse-current amplitude addi-
tionally reinforces the arc pressure on the molten bath For welding applications, two types of power sources
at the same effective value of the welding current [3]. are available, which are designed for a maximum
This way, both welding parameters, pulse frequency welding current of 500 A and 1000 A respectively,
and pulse-current amplitude, make the arc column fig. 5.
extremely stiff. This stiffness permits to increase the
welding speed. Even at high speeds a continuous
seam with good penetration is formed, fig. 3.
The figures 4a and 4b offer a comparison between the
arc formation of non-pulsed TIG welding and high-
frequency pulsed welding. With non-pulsed TIG weld-
ing, the arc silhouette shows deformations in the op-
posite welding direction, fig. 4b. The 6 kHz-pulsed arc
has a symmetric and more contracted shape, fig. 4a
[4]. In consequence, the arc is more stable.

Fig. 5. High-frequency- TIG- pulsed-welding power source

Fig. 4a. Arc formation of high-frequency TIG- pulsed-arc
welding [4],
f = 6 kHz, IP =375 A, Im = 292 A, vS = 2,0 m/min
shielding gas: 95% Ar + 5% H2
inverter
TIG 1000 DC
They have an inverter power module, which is char-
acterised by high efficiency and insensitivity towards
mains-voltage fluctuations. The pulse parameters are
set via a remote control, fig. 6. It enables the system
to pulse the welding current up to 8 kHz.

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 Fig. 7a. Weld formation of high-frequency TIG pulsed-arc welding
of an I-seam [4],
parent metal: 1.4301, t = 2 mm, f = 6 kHz,
Fig. 6. Remote control for high-frequency TIG pulsed welding, IP = 375 A, Im = 292 A, vS = 2,4 m/min, shielding gas:
operating elements 95%Ar + 5%H2, no filler metal

A power source only meets the requirements for opti-

mal current shapes (high, rectangular current pulses),
if it has very good dynamic features. However, this
makes anti-noise measures necessary in order to face
the noise pollution.
Special attention must be paid to the torch. The elec-
trode tip should display low surface roughness to
achieve long life at high current load. Equipping the
water-cooled torch with a gas lense is advisable.

3 Practical experiences and prospects

Areas of application of high-frequency TIG pulsed-arc

welding are continuously-fabricating welding automa-
tions of half-finished products such as tubes, foils and
strips, as well as the fabrication of parts, waste-gas
tubes, bellows or shapes, for instance.
Weldable metals are e.g. low- and high-alloy steels,
nickel-based alloys, copper and titanium alloys and
aluminium-based alloys These different materials re-
quire a careful selection of the shielding gas, since the
thermal flux of the arc is determined by the type and
the composition of the shielding gas [3].
Apart from argon/hydrogen mixtures (95% Ar / 5% H2),
argon/helium mixtures (50% Ar / 50% He) have turned
out to be suitable.
Welding experiments have been carried out mainly
with butt welds, fig. 7a and 7b [4]. The material thick-
ness was 2 mm. There, considerable differences con-
cerning the weld formation could be observed. While a
concentrated penetration was formed with 6kHz-
pulsed arc welding, fig. 7a, the typical TIG penetration
shape developed in the macrosection, fig. 7b, of non-
pulsed welding.
Fig. 7b. Weld formation of non-pulsed TIG welding of an
I-seam [4],
parent metal: 1.4301, t = 2 mm,
IS = 292 A, vS = 1,6 m/min,
shielding gas: 95%Ar + 5%H2, no filler metal
What makes the difference between both methods is
the achieved welding speed. The pulse heterodyning
resulted in a 50% increase under identical circum-
stances. In spite of an identical medium amperage of
292 A, the welding speed during non-pulsed operation
had to be reduced from 2.4 m/min to 1.6 m/min in
order to achieve complete fusion.
Another high-frequency TIG pulsed-arc welding cycle
at a tube of the same material thickness even brought
about a welding speed of 2.7 m/min,fig. 8.

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 Bibliography:

[1] Cui, H. u.a.:

Laserinduziertes Fokussieren des WIG- Lichtbo-
gens.
DVS- Berichte, Band 146, S. 139-143
(Cui, H. and others: Laser-induced focussing of the
TIG arc. DVS reports, volume 146, pp. 139-143)

[2] Killing, U.:

Geeignete Parameter fr das WIG- Impulslichtbo-
genschweien.
Jahrbuch Schweitechnik `94,
Fig. 8. Weld formation of high-frequency pulsed-arc welding
Deutscher Verlag fr Schweitechnik
at a tube; DVS- Verlag GmbH,
parent metal: 1.4301, t = 2 mm, vS = 2,7 m/min, Dsseldorf, 1993, S. 108 - 114
shielding gas: 95% Ar + 5% H2, no filler metal (Killing, U.: Suitable parameters for TIG pulsed-arc
welding. `94 Yearbook of welding technology,
A prerequisite to turn such a technology successfully German
into practice is the integration of power-source tech- publishing house for welding technology
nology, on the one hand, and process technology, on DVS GmbH, Dsseldorf, 1993, pp. 108-114)
the other hand.
The increase of the penetration at the same welding [3] Schellhase, M.:
speed or a higher welding speed at a given throat Der Schweilichtbogen - ein technologisches
opens up areas of application to TIG direct-current Werkzeug.
welding with high-frequency pulses that have been Fachbuchreihe Schweitechnik, Band 84,
restricted to multi-cathode or laser systems so far. The Deutscher Verlag fr Schweitechnik (DVS)
big advantages of this welding process are, above all, GmbH,
its considerably lower costs and the energy savings Dsseldorf, 1985, S.86, 97-99
compared with the previously mentioned systems. . (Schnellhase, M.: The welding arc - a technological
tool. Welding technology book series, volume 84,
DVS GmbH,
Dsseldorf, 1985, pp. 86, 97-99)

[4] Mller, S.:

Untersuchungen zum Hochfrequenz-WIG- Impul-
slichtbogenschweien.
Bericht der Schweitechnischen Lehr- und Ver-
suchsanstalt Fellbach (1997).
(Mller, S.: Examinations into high-frequency TIG
pulsed-arc welding. Report of the Schweitechnis-
che Lehr- und Versuchsanstalt Fellbach, 1997)

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