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INTRODUCTION
The Tungsten Inert Gas (TIG) welding is an arc welding process that uses an arc
between a tungsten electrode (nonconsumable) and the workpiece. An inert gas sustains
the arc and protects the molten metal from atmospheric contamination. The inert gas is
normally argon, helium or a mixture of argon and helium. The process may be used with
or without the addition of a filler metal. This process is also widely known as Gas Tungsten
Are Welding (GTAW). This process was developed in the late 1930s to provide a joining
method for aluminium and magnesium components of the aircraft, replacing riveting. This
process was then called Heli Arc process as helium was used as the inert shielding gas.
TIG welding is widely used as a fabrication tool in many industries because of high quality
welds produced by this process. The fundamentals of the process, the equipment, the
process procedures and variables, applications and safety considerations are discussed.

1. The Process
TIG welding process is illustrated in Fig-1.The process uses a nonconsumable tungsten
(or tungsten alloy) electrode held in a torch. Shielding gas is fed through the torch to
protect the electrode, molten weld pool, and solidifying weld metal from contamination by
the atmosphere. The electric arc is produced by the passage of current through the
conductive, ionized shielding gas. The arc is established between the tip of the electrode
and the work. Heat generated by the arc melts the base metal. Once the arc and weld
pool are established, the torch is moved along the joint and the arc progressively melts the
faying surfaces. Filler wire, is added to the leading edge of the weld pool to fill the joint.
Four basic components are common to all TIG welding setups, as illustrated in figure-2a.
a. Torch
b. Electrode
c. Welding power sourced.
d. Shielding gas
1.1 Advantages :
Produces high-quality, low-distortion welds
Free from spatter
Can be used with or without filler wire
Can be used with a range of power supplies
Welds almost all metals
Gives precise control of welding heat

 Allows excellent control of root pass weld penetration

The TIG process is applicable when the highest weld quality is required. It can be used to
weld almost all types of metals. The operator has excellent control of heat input, and
vision is not limited by fumes or smoke from the process.
1.2 Limitations.
Produces lower deposition rates than consumable electrode arc welding processes
Requires slightly more skill as compared to MIG or shielded metal are welding
(SMAW).
less economical for thick sections greater than 9.5 rnm.
Problematic in drafty environments because of difficulty in shielding the weld zone
properly
Additional problems with the process may include :
Tungsten inclusions if the electrode is allowed to contact the weld pool
Contamination of the weld metal, if proper shielding of the filler metal by the gas
stream is not maintained
Low tolerance for contaminants on filler or base metals
Arc blow or arc deflection, as with other processes

2. Welding Torches:
TIG welding torches hold the tungsten electrode, which conducts welding current to the
arc, and provide a means for conveying shielding gas to the arc zone.
Torches are rated in accordance with the maximum welding current that can be used
without overheating. A range of electrode sizes and different types and sizes of nozzles,
can normally be used in the same torch.
The heat generated in the torch during welding is removed either by gas cooling or water
cooling. Accordingly, the torches are called as Gas Cooled Torch or Water Cooled Torch.
Gas cooled torches provide cooling by the flow of the relatively cool shielding gas through
the torch. Gas cooled torches are used for maximum welding current of about 200
amperes.
In water-cooled torches cooling water enters the torch through the inlet hose, circulates
through the torch, and exits through an outlet hose. The power cable from the power

supply to the torch is enclosed within the cooling water outlet hose,Fig-2b. Water-cooled
torches are designed for use at higher welding currents in the range of 300 to 500
amperes. Most machine or automatic welding applications use water-cooled torches.
Tap water can be used to cool, water-cooled torches. In this case water flows through the
torch and then down a drain, or a closed system involving a reservoir, pump, and radiator
or water chiller to disperse heat from the system can be used.
2.1 Collets
Collets are used to grip the tungsten electrodes of various diameters in the electrode
holder. Good contact between the electrode and the inside diameter of the collet is
essential for proper current transfer and electrode cooling. Tungsten electrode of any
particular diameter will requier a collet matching size.
2.2 Nozzles :
Shielding gas is directed to the weld zone by gas nozzles or cups fitted onto the head of
the torch. Gas nozzles are made of various heat-resistant materials like ceramic metal,
metal jacketed ceramic, fused quartz, or other materials. They are made in different
shape, diameters and lengths. The gas nozzle or cup must be large enough to provide
shielding gas coverage of the weld pool area and surrounding hot base metal and the
stiffness needed to sustain coverage in drafts. A delicate balance exists between the
nozzle diameter and the flow rate. If the flow rate for a given diameter is excessive, the
effectiveness of the shield is destroyed because of turbulence. High flow rates without
turbulence requires large diameters, which are used at high currents. Size selection
depends on electrode size, type of weld joint, weld area to be effectively shielded, and
access to the weld joint.
Suggested gas cup sizes for various electrode diameters are listed in Table-1.
Gas Lenses:
Gas lenses are used to provide a laminar flow of shielding gas, Fig-3. These
attachments contain a porous barrier diffuser and are fitted around the electrode or collet
and remain inside the nozzles. With the gas lenses, it is possible to keep longer gap
between the nozzle and the work piece and to weld joints with limited accessibility
providing adequate shielding.

3. Electrodes :
Tungsten electrodes are nonconsumable because they do not melt or transfer to the weld.
The function of a tungsten electrode is to serve as one of the electrical terminals of the
arc, which supplies the heat required for welding. Its melting point is 3410 oC. Approaching
this high temperature, tungsten becomes thermionic; it is a ready source of electrons. It
reaches this temperature by resistance heating and, were it not for the significant cooling
effect of electrons boiling from its tip, resistance heating would cause the tip to melt. In

fact, the electrode tip is much cooler than that part of the electrode between the tip and
the externally-cooled collet.
3.1 Classification of Electrodes
Tungsten electrodes are classified on the basis of their chemical compositions, as
specified in Table-2 a as per AWS and in Table 2 b as DIN specifications.
Tungsten electrode sizes and current ranges are listed in Table-2, along with shield-gas
cup diameters recommended for use with different types of welding power.
Electrode Classifications : ( As per AWS )
Pure tungsten electrodes (EWP) contain a minimum of 99.5 percent tungsten, with no
intentional alloying elements. The current-carrying capacity of pure tungsten electrodes is
lower than that of the alloyed electrodes. Pure tungsten electrodes are used mainly with
AC for welding aluminium and magnesium alloys.
Thoriated Tungsten (EWTh):
The thermionic emission of tungsten can be improved by allaying it with metal
oxides that have very low work functions. As a result, the electrodes are able to handle
higher welding currents without failing. Thoriumoxide is one such additive. Two types of
thoriated tungsten electrodes are available. The EWTh-1 and EWTh-2 electrodes contain
1 percent and 2 percent thoriurnoxide (ThO2) called thoria, respectively, evenly dispersed
through their entire lengths.
Thoriated tungsten electrodes are superior to pure tungsten electrodes in several
respects. The thoria provides about 20 percent higher current-carrying capacity, generally
longer life, and greater resistance to contamination of the weld. With these electrodes, arc
starting is easier, and the arc is more stable than with pure tungsten orzirconiated
tungsten electrodes.
The EWTh-1 and EWTh-2 electrodes are designed for DCEN applications. They maintain
a sharpened tip configuration during welding, which is desirable for welding steel. They
are not used with AC because it is difficult to maintain the bailed end, which is necessary
with AC welding.
Ceriated Tungsten (EWCE) :
The EWCe-2 electrodes are tungsten electrodes containing 2 percent cerium oxide
(CeO2), referred to as ceria. Compared with pure tungsten, the ceriated electrodes exhibit

a reduced rate of vaporization or burn-off. EWCe-2 electrodes will operate successfully

with AC or DC.

Lanthanated Tungsten (EWLA) :

These electrodes contain 1 percent lanthanum oxide (LaO3), referred to as lanthanum.
The advantages and operating characteristics of these electrodes are very similar to the
ceriated tungsten electrodes.
Zirconiated Tungsten (EWZr):
Zirconiated tungsten electrodes (EWZR) contain a small amount of zirconium oxide
(ZrO2), as listed in table-1a & 1b. They are used for AC welding because they combine
the desirable arc stability characteristics and balled end typical of pure tungsten with the
current capacity and starting characteristics of thoriated tungsten. They have higher
resistance to contamination than pure tungsten, and are preferred for radio graphic-quality
welding applications where tungsten contamination of the weld are not desirable.
Electrode Tip Configuration :
The shape of the tungsten electrode tip is an important process variable in TIG welding.
Tungsten electrodes may be used with a variety of tip preparations. With AC welding, pure
or zirconiated tungsten electrodes forma hemispherical balled end. The size of the
hemisphere should not exceed 1-1/2 times the electrode diameter, otherwise it may falloff
while it is molten, Fig-4. For DC welding with thoriated, ceriated, or lanthanated tungsten
electrodes, the end is typically ground to a specific included angle, often with a truncated
end. In general, as the included angle increases, the weld penetration increases and the
width of the weld bead decreases.
Electrode Contamination :
Contamination of the tungsten electrode is most likely to occur when a welder accidentally
dips the tungsten into the molten weld pool or touches the tungsten with the filler metal.
The tungsten electrode may also become oxidized by an improper shielding gas or
insufficient gas flow, during welding or after the are has been extinguished. The
contaminated end of the tungsten electrode will adversely affect the arc characteristics
and may cause tungsten inclusions in the weld metal. If this occurs, the contaminated
portion of the electrode is removed.

4. Power Sources :
TIG power sources typically have either drooping or nearly true constant-current static
output characteristics, such as those shown in Fig-5. The static output characteristic is a
function of the type of welding current control used in the power source design.

A drooping volt-ampere characteristic is typical of magnetically controlled power source

designs including the moving coil, moving shunt, moving core reactor, saturable reactor, or
magnetic amplifier designs and also rotating power source designs. With a drooping
characteristic, the welder may vary the current level slightly by changing the arc length.
The advantages of magnetically controlled power sources are that they are simple to
operate require little maintenance and are relatively inexpensive. The disadvantages are
that they are large in size and weight and have a lower efficiency compared to
electronically controlled power sources. Also, most magnetic-control techniques are openloop which limits repeatability, accuracy, and response.
An essentially constant-current volt-ampere characteristic can be provided by
electronically controlled power sources, such as the series linear regulator, silicon
controlled rectifier, secondary switches, and inverter designs.
Inverter power sources are the most versatile, offering multi-process capabilities and
variable welding current waveform output. Inverters are also lighter and more compact
than other power source designs of equivalent current rating.
The advantages of electronically controlled power sources are that they offer rapid
dynamic response, provide variable current waveform output. Current pulsing have
excellent repeatability, and offer remote control.
Most truly constant current power sources are closed-loop controlled, in which the actual
current is measured and compared to the desired current setting. Adjustments are made
electronically within the power source to maintain the desired current as welding
conditions change. The disadvantages are that they are more complex to operate and
maintain and are relatively expensive.
It is important to select a TIG power source based on the type of welding current required
for a particular application. The types of welding current include AC sine-wave, AC squarewave, DC, and pulsed DC.
4.1 Direct Current :
Using direct current, the tungsten electrode may be connected to either the negative or
the positive terminal of the power supply. In almost all cases, electrode negative(cathode)
is chosen. With that polarity, electrons flow from the electrode to the work and positive
ions are transferred from the work to the electrode and the connection is known as DCEN
or (straight polarity) connection. When the electrode is positive (anode), the directions of
electron and positive ion flow are reversed, the connection is known as DGEP (reverse
polarity)connection.
With DCEN and a thermionic electrode such as tungsten, approximately 70 percent of the
heat is generated at the anode and 30percent at the cathode. Since DCEN produces the
greatest amount of heat at the workpiece, for a given welding current, DCEN will provide
deeper weld penetration than DCEP, Fig-6. DCEN is the most common configuration used
in TIG welding and is used with argon, helium, or a mixture of the two to weld most metals.

When the tungsten electrode is connected to the positive terminal (DCEP), a cathodic
cleaning action is created at the surface of the workpiece. This action occurs with most
metals but is most important when welding aluminum and magnesium because it removes
the refractory oxide surface that inhibits wetting of the weldment by the weld metal.
Unlike DCEN, in which the electrode tip is cooled by the evaporation of electrons, when
the electrode is used as the positive pole, its tip is heated by the bombardment of
electrons as well as by its resistance to their passage through the electrode. Therefore, to
reduce resistance heating and increase thermal conduction into the electrode collet, a
large diameter electrode is required for a given welding current when reverse polarity is
used. The current-carrying capacity of an electrode connected to the positive terminal is
approximately one-tenth that of an electrode connected to the negative terminal. DCEP is
generally limited to welding thin sheet metal.
4.2 Pulsed DC Welding :
Pulsed DC involves the repetitive variation in are current from a background (low) value to
a peak (high) value. Adjustments of the pulse current time, background current time, peak
current level, and background current level can be made to provide a current output
waveform suited to a particular application, Fig-7. Generally, pulse frequencies are
adjustable from 0.5 to 20 pulses per second. Pulsed DC is usually applied with the
electrode negative (DCEN).
In pulsed DC welding, the pulse current level is typically set at 2 to 10 times the
background current level. This combines the driving, forceful are characteristics of high
current with the low-heat input of low current. The pulse current achieves good fusion and
penetration, while the background current maintains the arc and allows the weld area to
cool.
There are several advantages of pulsed current. For a given average current level,
greater penetration can be obtained than with steady current, which is useful on metals
sensitive to heat input and minimizes distortion. Very thin metals can be joined with pulsed
DC. In addition, one set of welding variables can be used on a joint in all positions, such
as a circumferential weld in a horizontal pipe. Pulsed DC is also useful for bridging gaps in
open root joints.
4.3 Alternating Current :
Alternating current undergoes periodic reversal in welding current polarity from electrode
positive to electrode negative. Thus, AC can combine the work cleaning action of
electrode positive (reverse polarity) with the deep penetration characteristic of electrode
negative (straight polarity). AC welding is compared with DCEN and DCEP welding in Fig6.

Conventional AC welding power sources produce a sinusoidal open circuit voltage output.
The frequency of voltage reversal is typically fixed at the standard 50160 Hz frequency of
the primary power.
When the current decays to zero, different effects will occur, depending on the polarity.
When the thermionic tungsten electrode becomes negative, it supplies electrons
immediately to re-ignite the arc. However, when the weld pool becomes negative, it cannot
supply electrons until the voltage is raised sufficiently to initiate cold-cathode emission.
Without this voltage, the arc becomes unstable.
Some means of stabilizing the arc during voltage reversal is required with conventional
sinusoidal welding power sources. This has been done by using high voltage highfrequency sparks in parallel with the arc; and by using power supplies with a square wave
output.
Square wave AC welding power sources can change the direction of the welding current in
a short period of time. The presence of high voltage, coupled with high electrode and base
metal temperature at current reversals, allows the are to be re-ignited without the need for
an are stabilizer. Also, the lower peak" current of the square waveform tends to increase
the usable current range of the electrode. Since it is easier to provide the electrons
needed to sustain an arc when the electrode is negative, the voltage required also is less.
The result is a higher welding current during the DCEN interval than during DCEP. In
effect, the power supply produces both direct current and alternating current. Such
rectification can cause damage to the power supply due to overheating or, with some
machines, a decay in the output. Such rectification is eliminated by wave balancing. AC
waveforms are shown in Fig-8.
Early balanced-current power supplies involved either series-connected capacitors or a
DC voltage source (such as a battery) in the welding circuit. Modern power supply circuits
use electronic wave balancing. Balanced current flow is not essential for most manual
welding operations. It is, however, desirable for high-speed machine or automatic welding.
The advantages of balanced current flow are the following :
Better oxide removal
Smoother, better welding
No requirement for reduction in output rating of a given size of conventional welding
transformer (the unbalanced core magnetization that is produced by the DC
component of an unbalanced current flow is minimized).
The following are disadvantages of balanced current flow :
Larger tungsten electrodes are needed.

 Higher open-circuit voltages generally associated with some wave balancing

means may constitute a safety hazard.
Balanced wave welding power sources are more costly.
Some square wave AC power sources adjust the current level during the electrode
positive and electrode negative cycles at standard50160 Hz frequency. More expensive
power sources adjust the time of each polarity half cycle as well as the current level during
that half cycle. Such variable waveforms will adjust the welding current to suit a particular
application Fig-9.
Shielding Gases :
Shielding gas is directed by the torch to the are and weld pool to protect the electrode and
the molten weld metal from atmospheric contamination.

5. Types of Shielding Gases

Argon and Helium or mixtures of the two are the most common types of inert gas used fort
shielding. Argon-hydrogen mixtures are used for special applications.
5. 1 Argon :
Argon is approximately one and one-third times as heavy as air and ten times heavier
than helium. Argon, after leaving the torch nozzle, forms a blanket over the weld area.
Welding grade argon is refined to a minimum purity of 99.95 percent. This is acceptable
for TIG welding of most metals except there active and refractory metals, for which a
minimum purity of 99.997 percent is required.
Advantages of Argon :
Smoother, quieter arc action
Reduced penetration
Cleaning action when welding materials such as aluminium and magnesium.
Lower cost and greater availability
Lower flow rates for good shielding
Better cross-draft resistance
Easier arc starting due to low ionization potential of 2.52 x 10-18J (15 JeV)

The reduced penetration of an argon shielded arc is particularly helpful in vertical or

overhead welding since the tendency for the base metal to sag or run is decreased.
5.2 Heliurn :
Helium (He) is an inert, very light monatomic gas, having an atomic weight of four. It is
obtained by separation from natural gas. Welding grade helium is refined to a purity of at
least 99.99 percent. As Helium is lighter, it tends to rise around the nozzle and hence to
produce equivalent shielding effectiveness, the flow of helium must be two to three times
that of argon. The same general relationship is true for mixtures of argon and helium,
particularly those high in helium content.
For given values of welding current and arc length, helium transfers more heat into the
work than argon. The greater heating power of the helm are can be advantageous for
joining metals of high thermal conductivity and for high-speed mechanized applications.
Also, helium is used more often than argon for welding heavy plate. Mixtures of argon and
helium are useful when some balance between the characteristics of both is desired.
5.3 Argon-Hydrogen Mixtures :
Argon-hydrogen mixtures are employed in special cases, such as mechanized welding of
light gage stainless steel tubing, where the hydrogen does not cause adverse
metallurgical effects such as porosity and hydrogen-induced cracking. Increased welding
speeds can be achieved in almost direct proportion to the amount of hydrogen added to
argon because of the increased arc voltage. However, the amount of hydrogen that can be
added varies with the metal thickness and type of joint for each particular application.
Excessive hydrogen will cause porosity. Argon-hydrogen mixtures are limited to use on
stainless steel, nickel-copper, and nickel-base alloys.
The most commonly used argon-hydrogen mixture contains 15 percent hydrogen which is
used for mechanized welding of tight butt joints in stainless steel upto 0.062 in. (1.6mm)
thick. For manual welding, a hydrogen content of five percent is some times preferred to
obtain cleaner welds.
6. Gas Flow Rates :
Shielding gas flow requirements are based on cup or nozzle size, weld pool size, and air
movement. In general, the flow rate increases in proportion to the cross-sectional area at
the nozzle.
Backup Purge :
Backup purge gas can also be used to protect the underside of the weld and its adjacent
base metal surfaces from oxidation during welding. Uniformity of root bead contour,
freedom from undercutting, and the desired amount of root bead reinforcement are more

likely to be achieved when using gas backup under controlled conditions. In some
materials, gas backup reduces root cracking and porosity in the weld.
Argon and helium are satisfactory for the backup purge when welding all materials.
Nitrogen may be used satisfactorily for backup welds in austenitic stainless steel, copper,
and copper alloys. As a rule of thumb, a relatively inert atmosphere will be obtained by
flushing with four times the volume to be purged. After purging is completed, the flow of
backup gas during welding should be reduced until only a slight positive pressure exists in
the purged area. After the root and first filler passes are completed, the backup purge may
be discontinued.
When using argon or nitrogen, the backup gas should preferably enter the system at a low
point, to displace the atmosphere upwards and be vented at points beyond the joint to be
welded.

7. Arc Initiation :
With the power supply energized, and the shielding gas flowing from the cup, the torch is
lowered toward the workpiece until the tungsten electrode makes contact with the
workpiece. The torch is quickly withdrawn a short distance to establish the arc.
The advantage of this method of arc initiation is its simplicity of operation.
The disadvantage of touch starting is the tendency for the electrode to stick to the
workpiece, causing electrode contamination and transfer of tungsten to the workpiece.
High-Frequency Start :
High-frequency starting can be used with DC or AC power sources for both manual and
automatic applications. High-frequency generators usually have a spark-gap oscillator that
superimposes a high-voltage AC output at radio frequencies in series with the welding
circuit. The circuit is shown inFig-10. The high voltage ionizes the gas between the
electrode and the work, and the ionized gas will then conduct welding current that initiates
the welding arc.

8. Process Variables :
The main process variables in TIG welding are arc voltage (arc length), welding current,
travel speed, and shielding gas. The amount of energy produced by the arc is proportional
to the current and voltage. The amount transferred per unit length of weld is inversely
proportional to the travel speed. The arc in helium is more penetrating than that in argon.
However, because all of these variables interact strongly, it is impossible to treat them as
truly independent variables when establishing welding procedures for fabricating specific
joints.
8.1 Arc Current :

In general, arc current controls the weld penetration, the effect being directly proportional,
if not somewhat exponential.
The process can be used with either direct or alternating current, the choice depending
largely on the metal to be welded. Direct current with the electrode negative offers the
advantages of deep penetration and fast welding speeds. Alternating current provides a
cathodic cleaning (sputtering) which removes refractory oxides from the joint surfaces of
aluminum and magnesium, allowing superior welds to be made.
8.2 Arc Voltage :
The voltage measured between the tungsten electrode and the work is commonly referred
to as the are voltage. Arc voltage is a strongly dependent variable, affected by the
following
Arc current
Shape of the tungsten electrode tip
Distance between the tungsten electrode and the work
Type of shielding gas
When the other variables such as the shield gas, electrode, and current have been
predetermined, arc voltage becomes a way to control the arc length. Are length is
important with this process because pool width is proportional to are length. Therefore, in
most applications other than those involving sheet, the desired arc length is as short as
possible. But care should be taken to avoid possibility of short circuiting the electrode to
the pool or filler wire if the arc is too short.
8.3 Travel Speed
Travel speed affects both the width and penetration of a TIG weld, the effect being more
pronounced on width than on penetration. In mechanised welding travel speed is normally
given priority and other variables like current or voltage are adjusted accordingly. In other
cases, travel may be a dependent variable along with other variables selected to obtain
the required weld quality and uniformity.
8.4 Wire Feed :
In manual welding, the way filler metal is added to the pool influences the number of
passes required and the appearance of the finished weld.
In machine and automatic welding, wire feed speed determines the amount of filler
deposited per unit length of weld. Decreasing wire feed speed will increase penetration

and flatten the bead contour. Feeding the wire too slowly can lead to undercut, centerline
cracking, and lack of joint fill. Increasing wire feed speed decreases weld pen6rration and
produces a more convex weld bead.

9. TIG Welding Techniques :

The TIG process is used for manual as well as machine and automatic welding. Each
mode has its own advantages and limitations and the selection is made depending upon
the quality and quantity requirements and the available facility at the workshop and
economy of production.
9.1 Manual Welding :
In manual welding, the process functions like manipulation of the TIG torch, control of filler
metal additions, welding current, travel speed and are length are controlled by the
welder,Fig-11. Manual TIG welding is extensively employed for positional welding.
9.2 Machine Welding :
Machine welding is done with equipment that performs the welding operation under the
constant observation and control of a welding operator. Machine TIG welding provides
greater control over travel speed and heat input to the workpiece. The higher cost of
equipment to provide these benefits must be justified by production and quality
requirements.
Machine TIG welding equipment ranges from simple weld program sequencer and
mechanical manipulators to orbital tube and pipe welding systems. The sequencer
automatically starts and completes the weld, stepping from one variable setting to other
settings at predetermined times or locations along the weld joint. Part tolerances must be
controlled closely and fixturing must be strong, since the sequencer cannot compensate
for unwanted movement of the parts during welding. High precision part sand sturdy
fixturing increase production costs, but welding sequencers usually costless than more
sophisticated automatic controllers.
9.3 Automatic Welding :
In automatic welding the equipment performs welding operation without adjustment of the
controls by a welding operator. Some modern automatic welding systems (frequently
called adaptive or feedback control) make corrections to welding variables based on
information gathered during welding. The objective is to maintain weld quality at a
constant level in the presence of changing weld conditions.

10. Weld Preparation

10.1 Joint Tolerance :
The allowable tolerance of joint dimensions depends upon whether the welding is to be
done manually or by mechanized means. Manual welding applications can tolerate greater

irregularities in joint fit-up than mechanized welding. The particular tolerance for a given
application can be determined only by actual testing, and this tolerance should be
specified for future work.
10.2 Cleaning :
Cleanliness of both the weld joint areas and the filler metal is an important consideration
when welding with the gas tungsten arc process. Oil, grease, shop dirt, paint, marking
crayon, and rust or corrosion deposits all must be removed from the joint edges and metal
surfaces, to a distance beyond the heat-affected zone. Their presence during welding may
lead to arc instability and contaminated welds containing pores, cracks, and inclusions.
Cleaning maybe accomplished by mechanical means, by the use of vapor or liquid
cleaners, or by a combination of these. Organic solvents like carbon tetrachloride should
not be used as any trace of it coming under the arc may lead to formation of phosgene, a
toxic gas.Acetone may be used.

11. Discontinuities and Defects

11.1 Tungsten Inclusions
Tungsten inclusion is a discontinuity found only in TIG welding. Particles of tungsten from
the electrode can be embedded in a weld when improper welding procedures are used.
Typical causes are the following
Contact of electrode tip with molten weld pool
Contact of filler metal with hot tip of electrode
Contamination of the electrode tip by spatter from the weld pool
Exceeding the current limit for a given electrode size or type
Extension of electrodes beyond their normal distances from the collet (as with long
nozzles) resulting in overheating of the electrode.
Inadequate tightening of the holding collet or electrode chuck
Inadequate shielding gas flow rates or excessive wind drafts resulting in oxidation
of the electrode tip.
Defects such as splits or cracks in the electrode.

 Use of improper shielding gases such as argon-oxygen or argon-CO2 mixtures that

are used for gas metal are welding.
11.2 Lack of Shielding :
Discontinuities related to the loss of inert gas shielding are the tungsten inclusions,
porosity, oxide films and inclusions, incomplete fusion, and cracking. In addition, the
mechanical properties of titanium, aluminum, nickel, and high-strength steel alloys can be
seriously impaired with loss of inert gas shielding.

12. Application :
TIG welding process can be used to weld almost all metals. It is especially useful for
joining aluminium and magnesium, which form refractory oxides, and also for joining
reactive metals titanium and zirconium. This process is extensively used to join stainless
steels, copper, alloy steel and carbon steels.
In carbon steels, it is primarily used for root-pass welding with the application of
consumable inserts or open root techniques on pipes. This process finds applications
where quality and reliability of welded joint is more important than only cost
considerations. TIG welding is widely used to produce high quality joints required in the
aerospace and nuclear industries.
13. Safety in TIG Welding :
13.1 Gaseous and Metal Fumes Hazards
The major toxic gases associated in TIG welding are ozone, nitrogen dioxide and
phosgene gas. Metal fumes are also produced during welding due to the vaporization of
alloying elements. Particular care is required about those elements producing toxic fumes.
The ultraviolet rays emitted by the welding arc acts on the oxygen of the surrounding
atmosphere to produce ozone. The inert gases used in TIG welding, though are not toxic
in nature, can cause suffocation if accumulated in the breathing zone of the welding
personnel.
The toxic gas phosgene could be produced if chlorinated hydrocarbon cleaning agents,
such as trichloroethylene, perchloroethylene and carbon tetracholoride are present near
the welding arc. Hence these cleaning agents should not be used to clean the workpiece
or filler rod.
A good ventilation in the welding area is required so that the concentration of these gases
and fumes in the breathing zone of the welder remains well within the safe limit. If natural
ventilation is not adequate, or the welding area is a confined area or if toxic metal fumes
are produced, artificial ventilation systems like fume extractor should be provided.

13.2 Radiation Energy Hazard

Radiant energy may cause injury to the welder in two areas -- eye and the skin. Any
personnel, whether the welder, inspection personnel or the helper, present within the
immediate vicinity of a welding operation, should be adequately protected from the
radiation, particularly the ultraviolet radiation produced by the welding are. Generally the
highest ultraviolet radiant energy intensities are produced when argon shielding gas is
used and when aluminium or stainless steel is welded. For the protection of the eye, filter
glasses of proper shade depending on the welding current should be used. The
recommended shades for different welding current as prescribed in national / international
relevant safety standards and codes should be selected.