Hybrid Advances 3 (2023) 100066

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Hybrid Advances
journal homepage: www.journals.elsevier.com/hybrid-advances

Investigation on welding defects of alloys using TIG and MIG welding

Syed Rashedul Haque
Bangladesh Army, Shaheed Moinul Road, Dhaka Cantonment, 1206, Bangladesh

A R T I C L E I N F O A B S T R A C T

Keywords: This study is to look at the welding procedures of tungsten inert gas (TIG) and metal inert gas (MIG). This study
Welding focuses on welding flaws with different types of welding joints for AISI-1020 mild steel when welding with
Welding defect tungsten inert gas (TIG) and metal inert gas (MIG). The effects of various process factors on weld mild steel were
Welding using various alloys
investigated. The primary process parameters were modified in this research, and the influence on impact
TIG and MID welding
Welding faults
strength and hardness was investigated using destructive tests (tensile test). In a tensile test, the yield stress,
elastic stress, breaking stress, and breaking force were all measured. Non-destructive (NDT) testing was also
carried out. The ultrasonic and liquid penetration tests were carried out without causing any damage. Addi­
tionally, non-destructive testing (NDT) was done. The liquid penetration and ultrasonic tests were conducted
using non-destructive testing. A comparison of the two testing approaches also brought attention to the need of
outstanding weld quality. Fig. 12 shows the stresses in the tensile test for MIG welding, which are 204.793 N/
mm2 for yield, 27688 N/mm2 for elastic behavior, and 180 N/mm2 for breaking behavior. The welding link was
severed at 180 N/mm2 for MIG welding. The stresses for TIG welding are depicted in Fig. 13 as 313.633 N/mm2
(yield), 16506.2 N/mm2 (elastic), and 257.890 N/mm2 (breaking). The welding connection has failed at
257.890 N/mm2. Before welding, AISI-1020 mild steel had a breaking stress of 420 N/mm2. After welding, the
breaking stress was reduced and is now 257.890 N/mm2.

1. Introduction spots on the base metal surface are unstable [4]. As a result, the weld
bead will be flawed and inconsistent. When a trace quantity of an
Welding is one of the most essential processes in the manufacturing oxidizing gas, such as oxygen or carbon dioxide, is mixed with the
process. It is used to join metals by using metals or additives [1]. There shielding gas, arc stability improves and welding execution improves
are several welding processes available, such as laser welding, arc [5]. Ar–O2- or Ar–CO2–mixed gases are utilized for this type of tradi­
welding, friction welding, tungsten inert gas (TIG) welding, and metal tional metal inert gas (MIG) welding. Using these gases prevents
inert gas (MIG) welding [2]. The American Welding Society lists oxidation of the weld bead surface and an increase in the quantity of
frequent applications for welding as shipbuilding, infrastructure, pipe­ oxygen in the weld metal, both of which impair weld metal toughness
lines, mechanical structures, job shop fabrication, and repair work [3]. [6] (see Tables 1–5).
The two most prevalent gas-shielded arc welding processes are tungsten The manufacturing technique of welding uses coalescence to
inert gas (TIG) and metal inert gas (MIG) [2]. Metal joining is done using combine materials, often metals or thermoplastics [7]. A weld is created
the TIG and MIG welding methods in numerous industries. In compar­ by melting the work parts or adding filler metal to create a molten
ison to metal inert gas (MIG) welding using pure argon, tungsten inert substance that cools into a solid junction under pressure or heat. In
gas (TIG) welding produces weld beads with superior surfaces and fewer contrast, brazing and soldering have lower melting points between the
spatter (Ar). TIG welding has to be improved because of its slow speed work parts, allowing for the formation of a connection without the
and inadequate metal deposition. Although metal inert gas (MIG) melting of the work pieces [8]. Welding may be done with a variety of
welding is a very successful technology with high metal deposition rates, energy sources, such as gas flames, electric arcs, lasers, electric beams,
it still has to be improved in terms of quality, spatter production, bead friction, and ultrasound [3]. There are many different sorts of environ­
surface oxidation, and weld metal hardness [3]. Pure argon shielding gas ments where welding may be done, including open air, underwater, and
is suitable for MIG welding because it produces more durable welds. The in space. Since the turn of the 20th century, welding technology has
Metal Inert Gas (MIG) arc is unstable in pure argon because the cathode improved fast as a result of the need for durable and affordable joining

E-mail address: bd6seoi@senakalyan.com.

https://doi.org/10.1016/j.hybadv.2023.100066
Received 1 February 2023; Received in revised form 28 June 2023; Accepted 15 July 2023
Available online 24 July 2023
2773-207X/© 2023 The Author. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).
S.R. Haque Hybrid Advances 3 (2023) 100066

Table 1 Table 5
Welding parameter for TIG welding. The AISI 1020 physical properties of mild steel are.
Welding Factors of Factors of Factors of Welding Physical Properties Metric
parameter Level 1 Level 2 Level 3 position
Density 7.87 g/cc
Current (A) 130 150 160 Flat
Voltage (V) 18 23 24 Flat
Material 6 8 10 Flat continually improve the novel welding technique while learning more
thickness (mm)
about the qualities and characteristics of welds such as automatic sol­
Welding speed 165 175 185 Flat
(mm/min)
dering and tungsten inert gas welding [11]. Fig. 1 illustrated the TIG and
Stick out length 15 17 19 Flat MIG welding process.
(mm)
Welding angle 70 ◦
75 ◦
80 ◦
Flat 2. Methodology
Shielding gas (L/ 8 10 12 –
Min)
Arc length 1.2 1.2 1.2 – 2.1. Research of methodology
Shielding Argon Argon Argon –
This thesis’ supporting data and ideas originated from a number of
academic sources, including MAG welding manuals, research journal
articles relevant to its purpose, previous investigations, the company’s
Table 2
welding principle booklet, and several websites [3]. Finally, in the
Welding parameter for MIG welding.
study’s second step, which entailed exploratory approach based on the
Welding Factors of Factors of Factors of Welding selected welding parameters, issue analysis, numerical optimization,
parameter Level 1 Level 2 Level 3 position
and design and configuration were done [13].
Current (A) 120 140 164 Horizontal
Voltage (V) 16 21 22 Horizontal
2.2. Data collection method
Material 6 8 10 Horizontal
thickness (mm)
Welding speed 169 179 190 Horizontal The researcher utilized data collected from both primary and sec­
(mm/min) ondary sources.
Stick out length 15 18 20 Horizontal
(mm)
2.2.1. Primary data collection method
Welding angle 45◦ 40◦ 50◦ Horizontal
Shielding gas (L/ 8 10 12 – The new film was welded before the reworking process was carried
Min) out, and the primary data was acquired by direct observation by eye
Arc length 1.2 1.2 1.2 – inspection and employing liquid penetrants to identify welding faults
Shielding Argon Argon Argon –
[14].

2.2.2. Secondary data collection

Table 3 Secondary data was acquired from the corporate manual and data
The following table provides a description of AISI 1020 that had been recorded. This message was used to identify the many
carbon steel’s chemical make-up. kinds of flaws that regularly occur in the company’s unique line of
Element Content (%) trailers, and some of the fundamental causes of the problems were
discovered from this recorded information [15]. The third technique for
Manganese(Mn) 0.30–0.60
gathering secondary data for this thesis was via various sorts of litera­
Carbon(C) 0.18–0.23
Sulfur(S) 0.05 (max) ture reviews, such as published journal articles [16].
Phosphorous(P) 0.05 (max)
Iron(Fe) 98.81–99.26 2.3. Parameter selection

A variety of manipulating elements, such as welding settings, affect

Table 4 the degree of penetration and welding porosity of a welded joint.
The AISI 1020 mild steel’s mechanical characteristics are
included here. 2.4. Preparation of specimen
Mechanical properties Metric
Mild steel, stainless steel, and aluminum plates were cut from big
Hardness, Brinell 121
Hardness, Rockwell 68
sheets of each material in order to prepare the specimens for testing
Hardness, Vickers 126 [17]. According to ASTM-E8M, the test was performed and the specimen
Hardness, Knoop 140 was created. Milling and wear-cutting machines were used for the cut­
Tensile Strength, Ultimate 420 MPa ting procedure that shown in Fig. 3. A single V-grove has been created
Tensile Strength, Yield 350 MPa
between two plates to link them together for greater penetration [18].
Elongation at break 15%
Reduction of Area 40% The V-grove was created in both plates, at a 30-degree angle, from the
Modulus of Elasticity 186 GPa top and bottom halves of thickness as displayed in Fig. 2.
Bulk Modulus 148 GPa
3. Testing method
techniques during World Wars I and II [9]. When welding, safety pre­
3.1. Non-destructive test
cautions should be taken to prevent burns, electric shock, eye injury,
toxic gases, and excessive UV radiation exposure [10]. Blacksmiths
A number of testing and analytical techniques are referred to as "non-
utilized forge welding, which involves heating and pressing metals
destructive testing" (NDT) in order to analyze a material, component,
together, to unite them until the end of the 19th century. Researchers
structure, or system without endangering the integrity of the original

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 1. Welding process [12].

Fig. 2. Preparation of welding specimen [19].

Fig. 3(b). The cutting process by band saws.

Fig. 3(a). Specimen cutting process horizontal from a large sheet.

component [20]. In this study, two non-destructive tests are conducted:

an ultrasonic test and a liquid penetrant test.

3.2. Liquid penetrant test

Fig. 3(c). V-groove cutting by the milling machine.
Liquid penetrant examination is one of the Nondestructive Exami­
nation (NDE) methods that is most frequently employed. It is more precise steps for liquid penetrant testing might change from case to case.
inexpensive, versatile, and labor-intensive than other NDE approaches. The main phase, though, may be summed up as follows.
Liquid penetrant tests check for surface-visible material imperfections
by injecting a very thin liquid into a material imperfection and drawing 3.3.1. Surface preparation
the liquid out with a developer that mimics chalk [21]. Oil, grease, water, and other pollutants must not be present on the
surface since they may inhibit penetrants from reaching surface defects.
3.3. Steps of liquid penetrant test By using ORION 115D developer in Fig. 4(a, b, c)(a), the surface has
been prepped [22] that indicated in Fig. 4(b).
Based on a range of variables, including the penetrant system being
used, the size, and the substance of the components being inspected, the

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 4(a). ORION 115D developer.

Fig. 5(a). ORION 115P red dye penetrant. (For interpretation of the references
to colour in this figure legend, the reader is referred to the Web version of
this article.)

Fig. 4(b). Surface cleaning after use of developer.

3.4. Penetrant application

The penetrant substance ORION 115P Red Dye Penetrant in Fig. 5(a)
is sprayed over the welding area after the surface has been properly
cleaned and dried [22]. The penetrant is kept on the surface long enough
to give it the best chance to draw into or sleep into a flaw that shown in
Fig. 5(b). Application of penetrant.
Fig. 5(b).

is typically at least 10 min long.

3.5. Excess penetrant removal
3.7. Ultrasonic test
This stage of the inspection procedure is the most delicate because
excess penetrant must be removed from the sample’s surface, as illus­ Ultrasonic testing is a nondestructive testing technique intended to
trated in Fig. 6(a) and (b), while removing the least amount of penetrant find surface, subsurface, internal, and dimensional flows while allowing
feasible from faults. for a comprehensive volumetric analysis of the materials [24].
High-frequency sound waves are used in this kind of testing to thor­
3.6. Developer application oughly investigate the substance being tested by propagating them
throughout it.
To bring trapped penetrant defects back to the samples surface that
shown in Fig. 7(a) and (b) where they will be visible, a small coating of ❖ Ultrasonic inspection may detect both exterior flaws like seams and
the developer is then applied. The developer is given enough time to fractures as well as inner issues like voids and the presence of slugs.
stand on the surface of the component so that the trapped penetrant may
be removed from any surface imperfections [23]. This development time

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 7(b). Inspection welding defect.

Fig. 6(a). Surface before cleaning.
3.7.1. Working procedure
Ultrasonic testing involves the introduction of a high-frequency
sound wave into a material, where abnormalities in the material pro­
duce echoes that are felt. Transducers can be connected to program
scanning machinery or moved manually over components to conduct
inspections.
The welded work parts are subjected to the test. The equipment is
first calibrated, and the Distance Amplitude Curve (DAC) is then pro­
duced using a notched plate made of the same material. The DAC is first
drawn at an echo level of 80%, followed by 40%, then 20%. If the echo
goes across the curve, there is a fault that has to be looked at. The angle
probe must be positioned so that the crystal faces the weld region in
order to get an echo and detect the existence of defects. The probe is
moved in a zigzag pattern away from the weld center line, measuring the
distance on the weld’s right (RHS) and left (LHS) sides. Surface distance
(SD), beam path (BP/SP), and depth (D) parameters are all calculated.
ANOVA is used to determine if the data pertaining to the defect(s) is
adequate, and the impacts of factors are known in form of contribution,
as illustrated in the figure above.
Fig. 6(b). Surface after clean. The sample test result of an ultrasonic scan of MIG-welded material
on a mild steel plate with an 8 mm thickness is displayed below Fig. 8.
Echo signaling at a distance of 12 mm from the edge of the workpiece
during MIG welding underfill (see Fig. 10).
Below is an example of a test result from an ultrasonic scan of a mild
steel plate with an 8 mm thickness that was TIG welded. When TIG
welding, place the echo indicator at a distance of 32 mm from the work
piece’s edge.

3.8. Destructive test

Destructive testing is a technique for analyzing objects that involves

dismantling a particular material in order to evaluate its mechanical
properties, such as strength, toughness, flexibility, and hardness [25].
Destructive testing’s primary objective is to ascertain the product’s life
span as well as any design flaws.

3.9. Tensile test

Tensile testing is a destructive test that reveals details on the tensile

strength, yield strength, and ductility of the metallic material. Tensile
Fig. 7(a). Developer application on surface. tests were carried out using the universal testing machine [26]. The
universal testing machine for tensile testing is seen in Fig. 5(b). Tensile
❖ A mechanical vibration or pressure wave called an ultrasonic wave specimens were manufactured and tested in accordance with
has a vibration frequency that is substantially greater than that of ASTM-E8M and cut out from the plates using milling and wire cutting to
audible sound. their specified sizes. Photographs of several tensile specimens are shown
in Figs. 13 and 14.

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 8. Typical MIG welding with underfill and porosity.

Fig. 9. Lack of penetration in MIG welding, echo indicating at a distance of 12 mm from the edge of the workpiece.

Fig. 10. TIG welded material with porosity and lack of penetration.

4. Results and discussion 4.2. Ultrasonic test

4.1. Liquid penetration test The ultrasonic test was carried out utilizing ultrasonic testing
equipment. The faults discovered by this test are displayed in Figs. 15
The liquid penetration test was completed. As illustrated in the and 16. The echo in Fig. 15 demonstrates a lack of penetration 12 mm
image above, this test aids in the detection of problems such as blow from the edge of the workpiece for a MIG welding specimen. The echo in
holes and a lack of penetration. The faults of TIG welding are greater Fig. 16 indicates a lack of penetration at 11 mm from the edge of the
than those of MIG welding in the figure above. workpiece for a TIG welding specimen. Figs. 15 and 16 show that TIG
welding is superior to MIG welding.

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 11. Lack of penetration in TIG welding, echo indicating at a distance of 11 mm from the edge of the workpiece.

Fig. 12. Specimen preparation according to ASTM-E8M [26]

G-Gauge length 50 mm, W- Width 12.5 mm, A-Length of reduces section 57 mm, B-Length of grip section 50 mm, C-Width of grip section 20 mm, L-Overall length
200 mm, T-thickness 8 mm, R-Radius of fillet 12.5 m.

Fig. 13. Specimen for tensile test.

Fig. 14. Fractured Specimen after tensile test.

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 15. Lack of penetration in MIG welding, echo indicating at a distance of 12 mm from the edge of the workpiece.

Fig. 16. Lack of penetration in TIG welding, echo indicating at a distance of 11 mm from the edge of the workpiece.

Fig. 17. Tensile test stress-strain curve for MIG welding.

4.3. Tensile test parts to calculate the actual tensile load (KN), maximum tensile stress
(N/mm2), breaking load (KN), and breaking stress (N/mm2), and the
Tensile tests were performed on TIG and MIG welded mild metal results are shown in Figs. 15 and 16.

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S.R. Haque Hybrid Advances 3 (2023) 100066

Fig. 18. Tensile test stress strain curve for TIG welding.

4.3.1. Tensile test for MIG welding of mild steel (AISI-1020) welding are 204.793 N/mm2 (yield), 27688 N/mm2 (elastic), and 180
N/mm2 (breaking), as illustrated in Fig. 12. For the MIG welding pro­
Key Word Product Name cedure, the welding connection was broken at 180 N/mm2. The breaking
Test File Name MIG welding Method File Name Flat Bar Tensile Remake stress of AISI-1020 mild steel before welding was 420 N/mm2. The
Report Date 10-Oct-21 Test Date 10-Oct-21 breaking stress has been lowered after welding and is now 180 N/mm2.
Test Mode Single Test Type Tensile It might be because the specimen was quickly cooled with water, or it
Speed 5 mm/min Shape Plate
No of Batches: 1 Qty/Batch: 1
could be because the mechanical characteristics were altered when it
was sliced with a manual grinder. Fig. 13 shows the stresses for TIG
Name Thickness Width Gauge _Length
welding 313.633 N/mm2 (yield), 16506.2 N/mm2 (elastic), and
Unit mm mm Mm 257.890 N/mm2 (breaking). At 257.890 N/mm2, the welding connec­
MIG1 8.0000 26.1000 120.0000
tion has failed. The breaking stress of AISI-1020 mild steel before
For MIG welding, the following data has been found from the tensile test. welding was 420 N/mm2. The breaking stress has been lowered after
Yield stress = 204.793 N/mm.2. welding and is 257.890 N/mm2. It might be because the specimen was
Elastic stress = 27688 N/mm.2. quickly cooled with water, which affected the mechanical characteris­
Breaking stress = 180 N/mm.2. tics when it was chopped with a manual grinder.
Breaking force = 37709.3 KN.
All data has been shown in Fig. 17. 6. Conclusion

4.3.2. Tensile test for TIG welding of mild steel (AISI-1020) The welding of AISI-1020 mild steel comparable material by MIG
and TIG welding processes is done and examined in this research. To
Key Word Product Name
assure the identical material’s various flaws and mechanical depend­
Test File Name TIG1.xtak Method File Name Flat Bar Tensile Remark ability [3]. Mechanical parameters like tensile strength and ultimate
Report Date 10-Oct-21 Test Date 10-Oct-21
strength were evaluated. By taking into account the tiny experimenta­
Test Mode Single Test Type Tensile
Speed 5 mm/min Shape Plate tion values, this experiment produced a substantial outcome. TIG
No of Batches: 1 Qty/Batch: 1 welding is preferred for AISI-1020 because the welding joint generated
Name Thickness Width Gauge Length has higher tensile strength than MIG welding weld metal. The ultimate
strength and yield strength of AISI-1020 vary with welding location.
Unit mm mm mm
TIG1 8.0000 24.6000 120.0000
Increasing the voltage and current also increases the yield strength and
ultimate breaking strength. If we wish to raise the breaking stress of the
For TIG welding, the following data has been found from the tensile test. Yield welding joint in both the TIG and MIG welding processes, we can do so.
stress = 313.633 N/mm2 Elastic stress = 16506.2 N/mm.2.
The welded joint must be allowed to cool gently using air or sand after
Breaking stress = 257.890 N/mm.2.
welding.
Breaking force = 50.572 KN.
All data has been shown in Fig. 18.
Declaration of competing interest
5. Discussion
The authors declare that they have no known competing financial
This research and work involved the welding of AISI-1020 mild steel interests or personal relationships that could have appeared to influence
using the metal inert gas (MIG) and tungsten inert gas (TIG) welding the work reported in this paper.
processes. Fig. 7(b) shows the blow hole discovered during the liquid
penetration test. Blowing holes can arise as a result of excessively rapid References
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