Tig Rwti

TIG WELDING
TIG WELDING
Tungsten Inert Gas Welding.
Also termed as Gas Tungsten Arc
Welding (GTAW)
This is an ideal process for welding
of non-ferrous metal and stainless
steel in limited thickness.
 A.C. power source is used for
Aluminium.
D.C. power source is used for all
other metals.
In this process, an arc is struck
between a non consumable tungsten
electrode and the base metal.
The arc is shielded by inert gas
Argon (Ar), Helium (He) or a mixture
of both.
A filler wire may or may not be use.
Advantages of TIG welding –
1. High Quality- As the molten puddle is completely shielded
by an inert gas, the atmospheric oxygen and nitrogen is not
absorbed into the weld. Thus the weld is smooth and the
mechanical properties are better than other welding process.
2. Possible to weld all metals
3. Narrow HAZ, Deeper penetration and less Distortion.
4. No post weld cleaning necessary- There is no flux, no slag
and not post weld cleaning.
5. Less smoke or fumes.
6. Simple filler metal control.
7. No spattering.
8. Possible to weld thin section.
9. High thickness components can be welded.
10. Strength of weld is higher.
11. Simple Edge preparation.
12. Automation is easy- This process lends itself to
many forms of automatic welding.
13. All position welding
Limitation of TIG welding-
High Cost of welding – Due to cost of Argo gas,
tungsten electrode and power source.
Less productivity- Up to 1.5 kgs/arc hour can be
obtained in TIG welding. Due to this reason TIG
welding is used where quality is more important
than productivity.
High initial cost of equipments.
Not suitable for site work.
Application of TIG welding –
1. Aero space industries.
2. Nuclear reactors.
3. Chemical industries.
4. Fertilizer industries.
5. Power plant industries.
6. Steam generators.
7. Food and beverage tanks.
8. Oil and natural gas storage tanks.
Power Source and Equipments: The TIG
welding outfit consist of following –
1. Constant current power source A.C. or D.C.
2. High frequency high voltage spark unit or surge
injector.
3. Welding torch and combined welding cable.
4. Argon gas cylinder – with regulator, flow meter, gas
tubes with fittings.
5. Earth return cable.
6. Torch cooling arrangement in the case of water
cooled torch.
TIG WELDING
TIG WELDING Equipments
Welding torch and combined welding cable
Earth return cable

TIG Welding
Machine
TIG WELDING TORCH
TIG WELDING
16 ENBE 499
Ignition of Arc:
To ignite the arc, electrode is brought

06 mm from the work with high frequency
current and the welding current is switch on.
Once the inert gas is ionized, it become a
conductor of electricity.
TIG WELDING
TIG WELDING
Shielding Gases –
Argon and Helium are used for TIG welding.
Nitrogen is tried along with Argon for joining
copper and copper alloy.
The shielding gases provides the suitable ionizing
atmosphere for the arc.
The shielding gas, protect the weld pool.
Argon
Argon is a heavy inert mono-atomic gas.
Atomic weight of argon is 40.
It is obtain from the atmosphere by liquidification
of air, refined and transported as a liquid.
Argon can be obtained at 99.99 % purity.
Argon is generally considered better shielding gas for
TIG welding.
It provides better control of weld puddle.
Argon provide a more perfect shielding as it is a
heavier than air.
Helium
Helium is a light, mono-atomic gas.
Atomic weight of helium is 4.
All commercial helium is extracted from
natural gas.
It is lighter than air.
Higher flow rate is required than argon.
TIG WELDING - ELECTRODE
Tungsten Electrode –
In TIG welding, the electrode should by definition
be non-fusible tungsten.
The electrode are obtained in ground finish form
or chemically cleaned and etched.
Melting point of tungsten is 3380°C.
Boiling point of tungsten is 5950°C.
So that the little vaporization in the arc.
The electrode may be pure tungsten but is more
generally of tungsten alloyed.
continue
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Classification of electrode (as per AWS, A5.12-92) -

AWS
% of Alloying Elements Color Code
Classification
EWP 0% - PURE TUNGSTEN GREEN
EW-Th-1 0.8-1.2 % - THORIATED YELLOW
EW-Th-2 1.7-2.2 % THORIATED RED
EW-Zr-1 0.15-0.40 % ZIRCONIATED BROWN
EW-Ce-2 1.8-2.2 % CERIATED ORANGE
EW-La-2 0.9-1.2 % LANTHANTED BLACK
EWG NOT SPECIFIED GRAY
continue
E = Electrode
W = Tungsten, also called Wol-fram
P = Pure tungsten
G = Unspecified oxide additions
Example – EW Th – 1, i.e. a thoriated tungsten
electrode contains nominally 1Wt % thorium.
continue
1. EWP – Pure tungsten electrodes are used mainly with A.C.

current for welding of Al and Mg alloys.
2. EWZr-1 - Zirconiated tungsten electrode.
Those are normally the electrode of choice for A.C. current
for Al and Mg alloys.
3. EW-Th-1 and EW-Th-2 – Welding of steel, nickel alloy most
alloys other than Al and Mg. thoriated electrodes are not
normally used with A.C. current.
4. EW-Ce-2 – They also tent to have longer life than thoriated
electrodes. It will operate successfully with AC or DC current.
5. EW-La-2 – Similar to EW-Ce-2 and EW-Th-2 in operating
characterstics.
TIG ELECTRODE
For most TIG welding jobs,
Sharp, Pointed Electrode is used for

welding with DCSP
Rounded or Balled, Electrode end is used

for welding with AC.
TIG WELDING
Filler wire for TIG welding –
Filler wire is chosen according to the requirement.
Filler wires are available in the spool for
0.5,0.8,1.2,1.6,2.0,2.4,3.2 mm in diameter and in
some case 4.0 mm may also available.
In case suitable filler wire is not available a
strip is cut from the base metal and used as a
filler wire.
TIG WELDING
TIG Problems and Solutions
1) POOR GAS COVERAGE LEADS TO CONTAMINATION
 Weld contamination can occur when shielding gas is not turned
on.
 Check the gas cylinder label to make sure you’re using the right
type of gas for TIG welding.
 Set the proper gas flow rate, which should be 15 to 20 cubic ft per
hour.
 Consider using a gas lens instead of the standard collet body to
provide better gas shielding.
 Check all fittings and hoses for leaks.
 If everything else checks out, you may have moisture in your tank.
This doesn’t happen often – check with your gas supplier.
TIG WELDING continue
(2) WELDING ALUMINUM IN THE WRONG

POLARITY/ADJUSTING BALANCE
You should generally always TIG-weld aluminum with
alternating current (AC).
 Welding with direct current (DC) will make it difficult to
eliminate the aluminum oxide layer. This oxide layer can
mix with the filler metal, contributing to contamination.
The electrode positive (EP) portion of the AC cycle etches
away the oxide, while the electrode negative (EN) portion
melts the base metal.
Only start welding once the puddle has a shiny appearance.
This is how you know the oxide is removed and you are
ready to add filler metal.
(3) WELD GRAININESS

The grainy appearance of the weld bead is
typically caused by welding too hot causing too
much base metal dilution.
Find that “sweet spot” that is not too hot and not
too cold, and this graininess will go away.
You may have the wrong type of filler metal.
Always remove all grease, oil, and moisture from
the filler and base metal.
(4) LACK OF FUSION

Lack of fusion at the root of a T-joint or a fillet weld
can be caused by a number of factors:
 improper fit-up, holding the torch too far away from the
joint (increasing arc length) and improperly feeding the
filler rod, to name a few.
(a) Reducing arc length will provide better directional
control and help increase penetration. It is also important
not to under-fill the joint or weld too quickly.
(b) Inverter-based power sources offer greater control
over arc performance allowing you to tailor the arc to be
more focused into the puddle.
(5) CRATERS
Craters occur at the end of the weld and lead to cracking. Causes
include instantly dropping the weld power and removing the
filler rod too quickly. Adjust your technique and continue to feed
the filler rod while slowly reducing current at the end to fill in the
crater. Using a TIG welder with a “crater control” function may also
help.
(6) DIRTY BASE AND/OR FILLER METAL
All base and filler metals need to be cleaned, whether it’s mill scale,
oxide on aluminum, or dirt and grease. Grind, brush and wipe away
all potential contaminants. For cleaning aluminum, dedicate a
stainless steel brush to the task to prevent contamination from other
metals. Never use brake cleaner!
(7) SUGARING ON STAINLESS

Sugaring (oxidation) occurs around the weld when it is
exposed to oxygen in the air. The best way to prevent
sugaring is to ensure you have adequate gas coverage
on the front and back of the weld and to be sure that
you do not overheat the weld.
(8) TOO MUCH AMPERAGE ON ALUMINUM
Setting the amperage too high on aluminum creates a
wider profile, an ill-defined bead and can potentially lead
to burn-through. To solve this problem, reduce amperage
and/or increase travel speed.
(9) PROPER ARC LENGTH CONTROL

The color change in the middle of this aluminum
weld bead can result from an increase in arc length
(arc length is directly proportional to voltage).
 Holding too long of an arc increases overall heat
input, increases the potential for distortion, widens
the weld bead while decreasing penetration and
affects weld bead appearance.
Practice holding a consistent arc length to improve
heat input control and weld bead quality.
(10) POOR COLOR ON STAINLESS

Discoloration on a stainless steel weld is caused by
atmospheric contamination.
 Excessive discoloration could be caused by
overheating and could degrade its corrosion
resistance and mechanical properties, making the
weld rejectable; and the only solution would be to
scrap the part and start over.
To prevent overheating, reduce amperage, slightly
increase travel speed or shorten the arc length.
Thank you

Tig Rwti

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What is TIG welding?

What are some advantages of TIG welding?

TIG WELDING

Welding torch and combined welding cable

Earth return cable

To ignite the arc, electrode is brought

Classification of electrode (as per AWS, A5.12-92) -

1. EWP – Pure tungsten electrodes are used mainly with A.C.

Sharp, Pointed Electrode is used for

Rounded or Balled, Electrode end is used

(2) WELDING ALUMINUM IN THE WRONG

(3) WELD GRAININESS

(4) LACK OF FUSION

(7) SUGARING ON STAINLESS

(9) PROPER ARC LENGTH CONTROL

(10) POOR COLOR ON STAINLESS

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