Cairo University Faculty of Engineering

Mechanical Engineering Department

Second Year Mechanical

Report on:
Gas Tungsten Arc Welding

Submitted to: Dr/ Hassan Megahed

Submitted by:

Name Sec. B.N.

Mohamed Essam AboElftoh 5 17
Mohamed Amr Emad Zaki 5 20
Mohamed Mostafa Mohamed Mostafa Shehab 5 26

Mahmoud Ibrahim Elsayed Hassan 5 31

Mahmoud Ahmed Elsayed Kassab 5 33
Mahmoud Helmy Mohamed Imam 5 35
Mahmoud Ali Hassanen Ibrahim 5 37
Mahmoud Farag Hassan Saleh 5 39
Abstract
Tungsten inert gas welding (TIG) represents one of the most widely
used metal joining processes in industry. Its propensity to generate a
greater portion of welding fume particles at the nanoscale poses a
potential occupational health hazard for workers. However, current
literature lacks comprehensive characterization of TIG welding fume
particles. Even less is known about welding fumes generated by welding
apprentices with little experience in welding. We characterized TIG
welding fume generated by apprentice welders (N = 20) in a ventilated
exposure cabin. Exposure assessment was conducted for each apprentice
welder at the breathing zone (BZ) inside of the welding helmet and at a
near-field (NF) location, 60cm away from the welding task. We
characterized particulate matter (PM4), particle number concentration
and particle size, particle morphology, chemical composition, reactive
oxygen species (ROS) production potential, and gaseous components.
The mean particle number concentration at the BZ was 1.69E+06
particles cm−3, with a mean geometric mean diameter of 45nm. On
average across all subjects, 92% of the particle counts at the BZ were
below 100nm. We observed elevated concentrations of tungsten, which
was most likely due to electrode consumption. Mean ROS production
potential of TIG welding fumes at the BZ exceeded average
concentrations previously found in traffic-polluted air. Furthermore,
ROS production potential was significantly higher for apprentices that
burned their metal during their welding task. We recommend that future
exposure assessments take into consideration welding performance as a
potential exposure modifier for apprentice welders or welders with
minimal training.

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Table of Contents
Introduction ............................................................................................................... 5
1. Safety .................................................................................................................... 6
1.1 Electric shock can kill. ...................................................................................... 6
1.2 Fumes and gases can be hazardous to your health. ........................................ 6
1.3 Welding can cause fire or explosion. ................................................................ 6
1.4 Arc rays can burn eyes&skin Noise can damage hearing. ............................... 6
1.5 Hot parts can cause injury................................................................................ 6
2. Welding process .................................................................................................... 7
2.1 Principle of the process.................................................................................... 7
2.2 Working ........................................................................................................... 7
2.3 Welding Process .............................................................................................. 7
3. Equipment ............................................................................................................. 8
3.1 Power source ................................................................................................... 9
3.2 Filler wire ....................................................................................................... 10
3.3 Flowmeter ...................................................................................................... 10
3.4 TIG Torch ...................................................................................................... 11
4. Shielding gases ................................................................................................... 12
4.1 TIG welding with pure Argon .......................................................................... 12
4.2 TIG welding with Helium ................................................................................ 12
4.3 TIG welding with Hydrogen ............................................................................ 13
4.4 TIG welding with an Argon Shielding Gas Mixture ......................................... 13
5. Welding Joints ..................................................................................................... 14
5.1 Lap joint ......................................................................................................... 14
5.2 T-joint ............................................................................................................ 14
6. Characteristics of current types for GTAW........................................................... 14
7. Advantages & limitation ....................................................................................... 15
7.1 Advantages of TIG welding ............................................................................ 15
7.2 Limitation of TIG welding ............................................................................... 15
8. TIG Welding Applications .................................................................................... 16
Conclusion ............................................................................................................... 17
References.............................................................................................................. 18

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List of Figures

Fig. (1) Electric Shock. .................................................................................... 6

Fig. (2) Inhaling fumes and Gases. .................................................................. 6

Fig. (3) Fire due to welding. ............................................................................. 6

Fig. (4) Wearing helmet for safety. ................................................................... 6

Fig. (5) Heat Injury.. .…...........................………………………………………....6

Fig. (6) Welding Process. ................................................................................. 7

Fig. (7) TIG welding Equipment ...................................................................... 8

Fig. (8) Power Source . .................................................................................... 9

Fig. (9) Flowmeter ......................................................................................... 10

Fig. (10) TIG Torch Components. .................................................................. 11

Fig. (11) ) TIG welding with pure Argon ......................................................... 12

Fig. (12) Lap joint.. ......................................................................................... 14

Fig. (13) T-joint............................................................................................... 14

Fig. (14) Current types for TIG. ...................................................................... 14

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Introduction
Tungsten inert gas welding process also called as gas tungsten arc
welding is named so because it uses a) electrode primarily made of
tungsten and b) inert gas for shielding the weld pool to prevent its
contamination from atmospheric gases especially when joining high
strength reactive metals and alloys such as stainless steel, aluminum and
magnesium alloys, wherever high quality weld joints need to be
developed for critical applications like nuclear reactors, aircraft etc.
Invention of this process in middle of twentieth century gave a big
boost to fabricators of these reactive metals as none of the processes
(SMAW and Gas welding) available at that time were able to weld them
successfully primarily due to two limitations a) contamination of weld
from atmospheric gases and b) poor control over the heat input required
for melting. Moreover, welding of aluminum and its alloys with shielded
metal arc welding process can be realized using halide flux coated
electrodes by overcoming the problems associated with Al2O3, however,
halides are very corrosive and therefore welding of aluminum is
preferable carried out using inert shielding environment with the lerp of
processes like GTAW and GMAW.

Despite of so many developments in the field of welding, TIG process is

invariably recommended for joining of thin aluminum sheets of thickness
less than 1mm.

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1. Safety
1.1 Electric shock can kill.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Do not touch live electrical parts.

• Keep all panels and covers securely in place. Fig. (1) Electric Shock

1.2 Fumes and gases can be hazardous

to your health.
• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

Fig. (2) Inhaling fumes and Gases

1.3 Welding can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

Fig. (3) Fire due to welding

1.4 Arc rays can burn eyes&skin Noise

can damage hearing.
• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection. Fig. (4) Wearing helmet for safety

1.5 Hot parts can cause injury.

• Allow cooling period before touching welded metal.

• Wear protective gloves and clothing.

Fig. (5) Heat Injury

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2. Welding process
2.1 Principle of the process
In TIG welding, electric arc occurs when electricity is passed to the
tungsten electrode. The distance between the tip of the tungsten electrode
and the work piece surface will cause a flow of electrons. The flow of
electrons in turn produces arc and high heat to melt metal.
During extended inert gas welding gas cylinder through the blowpipe
from functioning as a shield to protect the molten crater of atmospheric
air trapped in it.

2.2 Working
First, a low voltage high current supply supplied by the power source to
the welding electrode or tungsten electrode. Mostly, the electrode is
connected to the negative terminal of power source and work piece to
positive terminal.
This current supplied form a spark between tungsten electrode and work
piece. Tungsten is a non –consumable electrode, which give a highly
intense arc.
The shielded gases like argon, helium is supplied through pressure valve
and regulating valve to the welding torch. These gases form a shield
which does not allow any oxygen and other reactive gases into the weld
zone. These gases also create plasma which increases heat capacity of
electric arc thus increases welding ability.
For welding thin material no filler metal is required but for making
thick joint some filler material used in form of rods which fed manually
by the welder into welding zone.

2.3 Welding Process

Fig. (6) Welding Process.

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• Arc is stuck between the non-consumable tungsten electrode and the work
piece to fuse metals.
• Arc is covered by a layer of shielding gas which acts as the flux and keeps
the nitrogen and oxygen in the air from coming in contact with the molten
puddle.
• When the puddle is formed on the base metal, the torch is moved along
the joint until the workpiece is fused together.
• A filler rod is may or may not be used.
• If a filler rod is used, it should be the same composition as the base metal.
• The filler rod is fed manually into the leading edge of the puddle.
• The torch may be moved in a semicircular motion to vary the width of the
bead.

3. Equipment
The equipment used for TIG is somewhat different from that used in
stick welding and much different from that used in MIG welding.

Fig. (7) TIG welding Equipment.

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3.1 Power source
The first unit of equipment is the power
source. A high current power source is needed
for TIG welding. It uses both AC and DC
power source, but in both the output is termed
a drooping, or constant current characteristic;
the arc voltage/welding current relationship
delivers a constant current for a given power
source setting.
Fig. (8) Power Source.
TIG welding normally uses constant current type of power source with
welding current ranging from 3-200A or 5-300A or higher and welding voltage
ranging from10-35V at 60% duty cycle. Pure tungsten electrode of ball tip
shape with DCEN provides good arc stability. Moreover, thorium, zirconium
and lanthanum modified tungsten electrodes can be used with AC and DCEP,
as coating of these elements on pure tungsten electrodes improves the electron
emission capability which in turn enhances the arc stability. TIG welding with
DCEP is preferred for welding of reactive metals like aluminum to take
advantage of cleaning action due to development of mobile cathode spots in
work piece side during welding which loosens the tenacious alumina oxide
layer. This helps to clean the weld pool. DCEN polarity is used for welding
metals such as carbon steel that don’t require much cleaning.

In TIG welding, the arc length is dependent on how consistently the welder
can hold the torch above the work piece. Arc length is directly proportional to
arc voltage, so a longer arc has a higher voltage and if the arc is shortened, the
voltage will decrease. Variation of arc length by 3 or 4mm can easily vary the
voltage by 5V. By design, the TIG power source has a limited range of current
and a reduced variation on changing voltage. With such a power source, the
variation of current over a variation of 5V might be as little as 10A, giving
almost imperceptible changes to the weld pool, making control much easier for
the welder.

The arc is usually started by High Frequency (HF) sparks which ionize the
gap between the electrode and the work piece. HF generates airborne and line
transmitted interference, so care must be taken to avoid interference with
control systems and instruments near welding equipment. When welding is
carried out in sensitive areas, a non-HF technique, and touch starting or 'lift
arc', can be used. The electrode can be short circuited to the work piece, but the
current will only flow when the electrode is lifted off the surface. There is,
therefore, little risk of the electrode fusing to the work piece surface and
forming tungsten inclusions in the weld metal. For high quality applications,
using HF is preferred.

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3.2 Filler wire
Filler metal is generally not used for welding thin sheet by TIGW. Welding of
thick steel plates by TIG welding to produce high quality welds for critical
applications such as joining of nuclear and aero-space components, requires
addition of filler metal to fill the groove. The filler wire can be fed manually or
using some wire feed mechanism. For feeding small diameter filler wires (0.8-
2.4mm), usually push type wire feed mechanism with speed control device is
used. Selection of filler metal is very critical for successful welding because in
some cases even use of filler metal similar to that base metal causes cracking of
weld metal especially when their solidification temperature range is every wide
(>50°C). Therefore, selection of filler wire should be done after giving full
consideration to the following aspects such as mechanical property
requirement, metallurgical compatibility, cracking tendency of base metal
under welding conditions, fabrication conditions etc.

For welding of aluminum alloys, Al-(5-12wt.%) Si filler is used as general-

purpose filler metal. Al-5%Mg filler is also used for welding of some
aluminum alloys.

Welding of different steels namely stainless steel with carbon or alloy steels
for high temperature applications needs development of buttering layer before
welding for reducing carbon migration and residual stress development related
problems.

3.3 Flowmeter
The flowmeter is used to adjust the flow of shielding gas and
is calibrated in cu. ft. per hour (cfh) or liters per minute
(L/min.), or both. To get a correct reading of the volume of
gas flow, the flowmeter must be installed in a vertical
position.

Water-cooled TIG welding units have three hoses going to

the torch .One hose will carry the shielding gas and is made of
plastic to prevent chemical reactions that might cause
contamination. One hose carries a combination of coolant and
the electrode lead. The lead is a woven metal tube with good
current-carrying capacity. The tube is covered by rubber or
plastic-insulating material. Current travels through the woven
metal tube, and coolant passes through the middle of the tube.
The third hose carries the return coolant to the storage
reservoir or to a drain. Light-duty torches are air-cooled, and
usually have only one hose connected to them, in which
passes a combination of electrode lead and shielding gas.
Fig. (9) Flowmeter

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3.4 TIG Torch
It is the most important part of TIG welding. This torch has three main
parts, tungsten electrode, collets and nozzle. A collet is primarily used to
hold the tungsten electrodes of varying diameters in position. Nozzle
helps to form a firm jet of inert gas around the arc, weld pool and the
tungsten electrode. The diameter of the gas nozzle must be selected
considering the expected size of weld pool so that proper shielding of the
weld pool can be obtained by forming a cover of inert gas. The gas nozzle
needs to be replaced at regular interval as it is damaged by wear and tear
under the influence of intense heat of the welding arc. Damaged nozzle
does not form uniform jet of inert gas around the weld pool for protection
from the atmospheric gases. Typical flow rate of shielding inert gas may
vary from 5-50 liters/min.

TIG welding torch is generally rated on the basis of their current

carrying capacity as it directly affects the welding speed and so the
production rate. Depending upon the current carrying capacity, the
welding torch can be either water or air cooled. Air cooled welding torch
is generally used for lower range of welding current than water cooled
torches.

Components
1. Torch head.

2. Handle.

3. Control switch.

4. Electrode cap.

5. Sealing ring.

6. Electrode collet.

7. Heat shield.

8. Collet body.

9. Gas nozzle.

Fig. (10) TIG Torch Components

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4. Shielding gases
As with other welding processes such as gas metal arc
welding, shielding gases are necessary in GTAW to protect the welding
area from atmospheric gases such as nitrogen and oxygen, which can
cause fusion defects, porosity, and weld metal embrittlement if they come
in contact with the electrode, the arc, or the welding metal. The gas also
transfers heat from the tungsten
electrode to the metal, and it
helps start and maintain a stable
arc.
The selection of a shielding
gas depends on several factors,
including the type of material
being welded, joint design, and
desired final weld appearance.

4.1 TIG welding with Fig. (11) TIG welding with pure Argon
pure Argon
Argon is the most commonly used shielding gas for GTAW, welders
have long relied on Argon for TIG welding because you can use it on
every type of metal. As long as you’ve got the right electrode and settings
in place, you can expect Argon to provide an effective shield for your
weld.
The arc for pure Argon shielding gas is narrow and concentrated so that
you can get a precise weld with significant penetration. The outer areas of
the arc will not heat up significantly while welding, and that means
there’s a chance you could have some undercutting or bead rollover while
you’re welding.
When used with alternating current, argon shielding results in high weld
quality and good appearance.

4.2 TIG welding with Helium

Helium is most often used to increase the weld penetration in a joint, to
increase the welding speed, and to weld metals with high heat
conductivity, such as copper and aluminum. A significant disadvantage is
the difficulty of striking an arc with helium gas, and the decreased weld
quality associated with a varying arc length.
Helium is used for most TIG welding jobs apart from mild steel. You
can use it for aluminum, stainless steel, and copper alloys.
Helium does an excellent job of conducting heat and creates a wide heat

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profile that reaches the edges of the weld puddle. However, with the
added heat come some challenges. For instance, you may need a high
frequency TIG start to get going.
It will also help to increase your gas flow rate in order to ensure you’re
protecting your weld puddle since Helium gas, even in this purified form,
tends to rise up once released into the atmosphere. Of course, once
you’ve jacked up the amount of Helium gas for shielding your weld,
you’ll also want to make sure you’re not burning through your metal
either!

4.3 TIG welding with Hydrogen

In some cases, welders working with stainless steel may opt to work
with hydrogen because it, much like Helium, increases the heat input
while welding. Welders typically use 5% or less of Hydrogen in their
shielding gas mixtures.
The advantage of Hydrogen for stainless steel is superior oxide removal
and a hotter, wider bead that penetrates deeper into the metal.

4.4 TIG welding with an Argon Shielding Gas

Mixture
Argon-Helium mixtures: are also frequently utilized in GTAW, since
they can increase control of the heat input while maintaining the benefits
of using argon.
Welders working with a Helium/Argon mix where Helium may be up to
50% of the shielding gas are able to enjoy significantly hotter welds while
working. By adding Helium into the mix, you can give your amperage a
significant boost; it is like adding another 20% of amperage. That really
helps when you just barely have enough amperage for the thick welds and
another benefit is that it welds cleaner too.
Normally, the mixtures are made with primarily helium and a balance of
argon. These mixtures increase the speed and quality of the AC welding
of aluminum and make it easier to strike an arc.
Argon-Hydrogen mixture: is used in the mechanized welding of light
gauge stainless steel, but because hydrogen can cause porosity, its uses
are limited.
Argon-Nitrogen mixture: can sometimes be added to argon to help
stabilize the austenite in austenitic stainless steels and increase
penetration when welding copper. Due to porosity problems in ferritic
steels and limited benefits, however, it is not a popular shielding gas
additive.

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5. Welding Joints
5.1 Lap joint
For a lap weld, form the weld pool so that the
edge of the overlapping piece and the flat surface
of the second piece flow together. Since the edge
will melt faster, dip the filler rod next to the edge
and make sure you are using enough filler metal to
complete the joint.
Fig. (12) Lap joint

5.2 T-joint
When welding a T-joint, the edge and the flat
surface are to be joined together, and the edge will
melt faster. Angle the torch to direct more heat to
the flat surface and extend the electrode beyond
the cup to hold a shorter arc. Deposit the filler rod
where the edge is melting.
Fig. (13) T-joint

6. Characteristics of current types for GTAW

Diagram

Fig. (14) Current types for TIG

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7. Advantages & limitation
7.1 Advantages of TIG welding
1) The TIG welding process is known for its consistency in producing
high quality welds.
2) Welds can be made either by applying filler rod to the puddle or by
fusing the base metal without a filler rod.
3) The welding process is easier than other methods because the welder
can clearly see the welding zone.
4) There is a minimal amount of smoke, fumes, and sparks created by the
TIG process.
5) The welding process is easier than other methods because the welder
can clearly see the welding zone.
6) The welding process is easier than other methods because the welder
can clearly see the welding zone.
7) There is usually less distortion of the work piece because of the small
heat affected zone.
8) Welds are not weakened by slag inclusion in the bead because the flux
used is a gas.
9) Provides precise control of welding variables (i.e. heat).
10) Welds made with a gas-shielded arc are more corrosion resistant,
more ductile, and stronger because the gas is able to completely exclude
atmospheric air from the welding zone.

7.2 Limitation of TIG welding

1) Slower than Consumable electrode processes.
2) Shield gases "Ar and He" are expensive.
3) Low Deposition Rate.
4) Requires high level of workers skill.

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8. TIG Welding Applications
TIG is most commonly used to weld thin sections of stainless steel and
non- ferrous metals such as aluminum, magnesium, and copper alloys.
Because TIG welding can be used with such a large variety of metals,
The process can be applied to several industries and aid in the creation
and repair of many items. This form of welding is common in the
aerospace, automotive, repair and art fields. For instance, here are some
types of TIG welding jobs:

Aerospace – The aerospace industry is one of the primary users of gas

tungsten arc welding. Aircraft and spacecraft are constructed in part by
means of TIG welding. So, the commercial planes used every day, as well
as complex craft like the International Space Station have benefitted from
such processes. It uses lite metals (Aluminum and its alloy) thin sheet and
need high quality welding as TIG welding which is known for its strength
and precision.

Automotive – Safe and secure construction is essential in the auto

industry, as is making vehicles stand the test of time. For these reasons,
TIG welding is widely used in the automotive industry. TIG strategies are
known to reduce corrosion over time, so car fenders are frequently
welded in this way to avoid rust. Besides this, the better the vehicle is
constructed, the safer it will be for those travelling in it.

Repair – TIG may be used in a number of repair applications. From

fixing a child’s toy, like a wagon or old-fashioned pedal car, to repairing
aluminum tools, this welding method comes in handy.

Art – TIG is touted for the superior cosmetic appearance it results in.
Artworks are about the artist’s message, yes, but they also rely on
appearance. Therefore, works like industrial fixtures or metal sculptures
may rely on TIG welding processes.

Others industry – TIG welding also used for others industrial purposes.
Such as for various piping, Joining thin material in automobile industry.

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Conclusion

Inert Gas Tungsten Arc Welding (Tungsten Inert Gas) is a type of arc
welding made the atmosphere control. Tungsten electrodes were used.
Electrodes only to produce an arc only. So, for the weld when the
metal Additional required to weld, trunk filler rod should be fed to the
weld area as methods done in oxy-gas welding process asetilina.
During the welding process is a shield in the form of gas inert (argon
and helium) is used to block the welded from atmospheric air. Shield
works for prevent oxidation at the electrode tip, a puddle weld and the
parent metal in the vicinity of the welded.
There are two types of commonly used welding nozzle weld TIG
operation manually. For welding use per current is low (less than 200
amperes) when welding thin material, weld nozzles are usually of the
type that can cooled in air conditioning. But, for welding require more
current than 200 amperes, the nozzle weld should be cooled with water
so that the electrodes do not become overheated.

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 References
1- Cary, Howard B.; Helzer, Scott C. (2005). Modern welding

technology. Upper Saddle River, New Jersey: Pearson Education.

2- Jeffus, Larry (2002). Welding: Principles and applications (Fifth ed.).

3- American Welding Society (2004). Welding handbook, welding

processes Part 1. Miami Florida: American Welding Society.

4- Characterization of Tungsten Inert Gas (TIG) Welding Fume

Generated by Apprentice Welders (n.d.). Retrieved from

https://academic.oup.com

5- Automatic Tungsten Inert Gas (TIG) welding using machine vision

(n.d.). Retrieved from https://ieeexplore.ieee.org/

6- How to Choose A Shielding Gas for TIG Welding (n.d.). Retrieved

from https://www.bakersgas.com

7- kinds of Shielding gas you use (n.d.). Retrieved from

http://www.weldingtipsandtricks.com

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