WELDING SCIENCE

TIG or GTAW

1
FIG 1

2
 Gas Tungsten Arc Welding (GTAW)
The heat for Gas Tungsten Arc Welding (GTAW)
is produced by an electric arc maintained
between a non-consumable tungsten electrode
and the part to be welded.
The heat-affected zone, the molten metal, and
the tungsten electrode are all shielded from the
atmosphere by a blanket of inert gas fed
through the GTAW torch.

3
 Gas Tungsten Arc Welding (GTAW)
Inert gas is that which is inactive, or deficient in
active chemical properties.
It does not burn, and adds nothing to or takes
anything from the metal.
Inert gases such as argon and helium do not
chemically react or combine with other gases.

4
 Gas Tungsten Arc Welding (GTAW)
They possess no odour and are transparent,
permitting the welder maximum visibility of the
arc.
In some instances a small amount of reactive
gas such as hydrogen can be added to enhance
travel speeds.

5
 Gas Tungsten Arc Welding (GTAW)
The torch holding the tungsten electrode is
connected to a shielding gas cylinder as well as
one terminal of the power source, as shown in
Figure 2.

6
FIG 2

7
 Gas Tungsten Arc Welding (GTAW)
The tungsten electrode is usually in contact with
a water-cooled copper tube, called the contact
tube, which is connected to the welding cable
(cable 1) from the terminal.
The workpiece is connected to the other
terminal of the power source through a different
cable (cable 2).

8
FIG 3

9
 Gas Tungsten Arc Welding (GTAW)
The shielding gas goes through the torch body
and is directed by a nozzle toward the weld pool
to protect it from the air.
Protection from the air is much better in GTAW
than in SMAW.

10
 Gas Tungsten Arc Welding (GTAW)
Autogenous GTAW welding (without filler metal)
is used in thin square edged sections (2mm),
while V and X type edge preparations are needed
in thicker sections.
A filler rod is needed for joining thicker
materials.
The autogeneous process is readily used in
robotics and automation techniques.

11
 Gas Tungsten Arc Welding (GTAW)
This process is extensively used for welding thin
components of stainless steel, aluminum,
magnesium or titanium alloys as well pieces of
carbon and low alloy steels.

12
 ARC in GTAW
The plasma temperature can range from 5000 K to
30000 K.
Energy is transferred from the arc to the metal being
welded by six principal mechanisms:
Major Factors

(1) conversion of kinetic energy in electrons and

ions,
(2) work function at the surface,
(3) radiation from the arc,
(4) thermal conduction,
(5) thermal convection, and
(6) resistance heating in the electrode.
13
 ARC in GTAW
The first two mechanisms listed, conversion of
kinetic energy and work function, are the main
conveyors of energy into the workpieces.

14
 POLARITY
DCEP, DCEN and AC can be used with GTAW.
Weld voltage is typically 20 to 40 volts, and weld
current varies from less than 125 amps for DCEP
to 1000 amps for DCEN.

15
 DCEP (electrode positive)
Aluminum and magnesium are two metals that
have a heavy oxide coating that acts as an
insulator and must be removed before successful
welding can take place.
With a positive polarity, however, a cleaning
effect takes place which is caused by the
impact of the positive charged ions from the
shielding gas atmosphere on the negative
charged work surface, thus destroying the oxide
skin. 16
 DCEP (electrode positive)
The cleaning action is most effective when argon
serves as shielding gas.
Helium is ineffective because of low particle
mass, but a small addition of argon to a heIium
shield can remedy this shortcoming.

17
DCEP (electrode positive)

18
 AC
When alternating current (ac) is used for
welding, the electro-mechanics just reviewed for
the direct current (dc) arcs still apply in a general
way, but the arc is extinguished at each half cycle
when the current falls to zero.
Therefore balanced 50:50 heat is obtained on
electrode and the workpiece.

19
 ELECTRODE
Tungsten is preferred for this process because it has
the highest melting point of all metals.
The tungsten electrode establishes and maintains
the arc.
It is said to be a nonconsumable in that the
electrode is not melted and included in the weld
pool.
In fact, great care must be taken so that the
tungsten does not contact the weld pool in any way,
thereby causing a contaminated, faulty weld.
20
 ELECTRODE
This is generally referred to as a tungsten inclusion.
Tungsten electrodes for GTAW come in a variety of
sizes and lengths.
They may be composed of pure tungsten (AC), or a
combination of tungsten and other elements such as
thorium(DC), or zirconium (AC), respectively.
These alloying elements are added to provide better
current-carrying & electron-emission characteristics
and longer electrode life.
21
 ELECTRODE
The percentage of alloying elements may range
between 1 to 2%.
Electrodes come in standard diameters from
1/100" through 1/4.
Lengths of tungsten may also vary from 3 " to
24 ".
7" length is the most commonly used.

22
Typical Electrode Tip Shapes

DCEN DCEN AC DCEN

&
DCEP

23
 SHIELDING GAS
Primarily two inert gases are used for shielding
purposes for TIG.
They are argon and helium.
Argon, with an atomic weight of 40, is about one
and a half times heavier than air and ten times
heavier than helium which has an atomic weight
of 4.

24
 AR & HELIUM
Argon and helium are the major shielding gases
used in gas tungsten arc welding.
In some applications, mixtures of the two gases
prove advantageous.
To a lesser extent, hydrogen is mixed with argon
or helium for special applications.
Note: CO2 cannot be used in this process since it
provides inadequate protection for the hot
tungsten electrode as it tends to oxides the
electrode.
25
 ARGON
Argon is most commonly used of the shielding
gases.
Excellent arc starting and ease of use make it
most desirable for manual welding.
Argon produces a better cleaning action when
welding aluminum and magnesium with
alternating current.
The arc produced is relatively narrow.
Argon is more suitable for welding thinner
material.
26
 ARGON
Argon produces less heat than helium.
Argon, with an atomic weight of 40, is about one
and a half times heavier than air and ten times
heavier than helium which has an atomic weight
of 4.
Because of heavy mass it stays on the weld pool
and provides better shielding protection.
Argon produces deeper penetration and narrow
weld bead.
27
 HELIUM
At equal amperage, helium produces a higher
arc voltage than argon.
Since welding heat is the product of volts times
amperes, helium produces more available heat
at the arc.
This makes it more suitable for welding heavy
sections of metal that have high heat
conductivity, or for automatic welding operations
where higher welding speeds are required.
It improves the depth of fusion.
28
 HELIUM
Helium alone may be preferred for overhead
welding since it is lighter than air and flows
upward.
Arc initiation with helium is difficult as
compared to argon.

29
HELIUM

30
 ARGON + HELIUM
Argon-helium gas mixtures are used in
applications where higher heat input and the
desirable characteristics of argon are required.
Argon, being a relatively heavy gas, blankets the
weld area at lower flow rates.
Argon is preferred for many applications because
it costs less than helium.
Helium, being approximately 10 times lighter
than argon, requires flow rates of 2 to 3 times
that of argon to satisfactorily shield the arc.
31
 Advantages of the GTAW Process
1. Wide range of metal can be welded.
2. Dissimilar metals can also be joined such as
copper to brass and stainless to mild steel.
3. Narrow heat-affected zone
4. Less distorsion
5. No Slag: There is no requirement for flux with this
process; therefore, there is no slag to obscure the
welders vision of the molten weld pool.

32
 Advantages of the GTAW Process
6. No Sparks or Spatter, No Smoke or Fumes:
7. Improved metallurgical properties stronger,
more ductile and more corrosion resistant
joints.
8. Very thin metals can be welded due to the ease
of controlling the current.

33
 GTAW Disadvantages
The main disadvantage of the GTAW process is
the low filler metal deposition rate.
Another disadvantage is that the hand-eye
coordination necessary to accomplish the weld is
difficult to learn, and requires a great deal of
practice to become proficient.
The arc rays produced by the process tend to be
brighter than those produced by SMAW and
GMAW. This is primarily due to the absence of
visible fumes and smoke.
34
 GTAW Disadvantages
The increased amounts of ultraviolet rays from
the arc also cause the formation of ozone and
nitrous oxides.
Therefore, care should be taken to protect skin
with the proper clothing and protect eyes with
the correct shade lens in the welding hood.
Metal thickness of upto 7 mm can be welded
only.
Contamination of tungsten can cause
discontinuities in welding.
35
 APPLICATIONS
Aerospace application.
Welding of aluminium alloys, steel, copper,
nickel, tin & Zr.
Aircraft frames, Jet engine castings, Rocket motor
cases etc.
Precision welding of parts in atomic industry.
Pipe works required for high pressure steam
lines, chemical and petroleum industries.

36
 APPLICATIONS
Stainless steel, nickel and its alloys Ar + 5%
H(increase the arc heating efficiency)
Aluminium alloys Ar and He

37
 Sticking an arc
Arc ignition is achieved by 2 methods:
1. Touching the work piece with the electrode
and lifting it a few millimeters from the parent
material (contact ignition and lift ignition).

38
 Sticking an arc
2. by using a high frequency voltage discharge,
applied to the tungsten electrode.

39
 Sticking an arc
A gap of about 4 mm is maintained from the
tungsten electrode and the work piece. A high
frequency spark is generated, this ionizes the
air gap making it conductive, allowing the arc to
be established without touching the work piece
with the tungsten electrode, no tungsten
contamination can occur (High Frequency
ignition).

40