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GAS TUNGSTEN ARC WELDING
INTRODUCTION
Welding is a process of joining similar materials by application of heat with
or without application of pressure and addition of filler material. The result
is the continuity of homogenous material, of the composition and
characteristics of two parts which are being joined together.
TYPES OF WELDING
Modern methods of welding may be classified under two broad headings
1. Plastic welding
2. Fusion welding
These are also called pressure welding and, non-pressure welding
respectively.
PLASTIC WELDING
Unlike in fusion welding processes no liquid phase is present in the joint.
The principle of solid-state welding is best demonstrated by following
example. If two clean surfaces are brought into atomic contact with each
other under sufficient pressure (and in absence of oxide films and other
contaminants), they form bonds and produce a strong joint.
Applying external heat improves the bond by diffusion. Small interfacial
movements on the contacting surfaces of the two pieces to be joined
disturb the surfaces. Break up any oxide films, and generate new, clean
surfaces; this mechanism improves the strength of the bond. Heat may be
generated by friction, as well, an effect utilised in friction welding. Electricresistance heating is utilized extensively in resistance-welding processes.
In explosion welding, very high contact pressures are developed, to cause
welding on the surface
TIG WELDING
Gas Tungsten Arc Welding (GTAW) is frequently referred to as TIG welding.
TIG welding is a commonly used high quality welding process. TIG
welding has become a popular choice of welding processes when high
quality, precision welding is required.
In TIG welding an arc is formed between a non-consumable tungsten
electrode and the metal being welded. Gas is fed through the torch to
shield the electrode and molten weld pool. If filler wire is used, it is added
to the weld pool separately.
In TIG welding the filler material is supplied from a filler wire. Because the
tungsten electrode is not consumed in this operation, a constant and
stable arc gap is maintained at a constant current level. The filler metals
are similar to the metals to be welded, and flux is not used. The shielding
gas is usually argon or helium. Welding with GTAW may be done without
filler metals- for example, in the welding of close fit joints.
Depending on the metals to be welded, the power supply is either DC at
200 a, or AC at 500A. Maximum penetration is obtained with straightpolarity dc conditions. In general, AC is preferred for aluminium and
magnesium, because the cleaning action of AC removes oxides and
improves weld quality. Thorium or zirconium may be used in tungsten
electrodes, to improve their electron emission characteristics. Power
requirements range from 8 kW to 20 kW.
Contamination of tungsten electrode by the molten metal can be a
significant problem, particularly in critical applications, because it can
cause discontinuities in the weld.
The arc does not melt tungsten, which has a high melting point of over
3300 degree Celsius. The end of the welding gun where the arc is created
is either made of high impact ceramic of is water cooled.
The TIG welding process lends itself ably to the fusion welding of
aluminium and its alloys, stainless steel, magnesium alloy, nickelbase
alloys, copper-base alloys, carbon steel and low-alloy steel. It can also be
used for the combining of dissimilar metals, hard facing, and the surfacing
of metals.
TUNGSTEN ELECTRODE-The tungsten electrode use here is nonconsumable. Since tungsten has high melting point. Hence,
tungsten electrode does not melt during the welding process.
It is a slow process.
It is more expensive than MIG welding.
Highly skilled labour is required.
Welder has to work in high intensity of light.
APPLICATION OF TIG WELDINGThe TIG welding process is best suited for metal plate of thickness around
5- 6 mm. Thicker material plate can also be welded by TIG using multi
passes which results in high heat inputs, and leading to distortion and
reduction in mechanical properties of the base metal. In TIG welding high
quality welds can be achieved due to high degree of control in heat input
and filler additions separately. TIG welding can be performed in all
positions and the process is useful for tube and pipe joint. The TIG welding
is a highly controllable and clean process needs very little finishing or
sometimes no finishing. This welding process can be used for both manual
and automatic operations.
The TIG welding process is extensively used in the so-called high-tech
industry applications such as
I. Nuclear industry
II. Aircraft
most white metals, e.g. aluminium and magnesium. The heat input to the
tungsten is averaged out as the AC wave passes from one side of the
wave to the other. On the half cycle, where the tungsten electrode is
positive, electrons will flow from base material to the tungsten. This will
result in the lifting of any oxide skin on the base material. This side of the
wave form is called the cleaning half. As the wave moves to the point
where the tungsten electrode becomes negative the electrons will flow
from the welding tungsten electrode to the base material. This side of the
cycle is called the penetration half of the AC wave forms.
4.