Section 12

TIG Welding
12 TIG Welding
12.1 Process characteristics
In the US the TIG process is also called gas tungsten arc welding (GTAW). Melting is
produced by heating with an arc struck between a non-consumable tungsten
electrode and the workpiece. An inert gas shields the electrode and weld zone to
prevent oxidation of the tungsten electrode and atmospheric contamination of the
weld and hot filler wire (as shown below).

Figure 12.1 Manual TIG welding.

Tungsten is used because it has a melting point of 3370°C, well above any other
common metal.

12.2 Process variables

The main variables in TIG welding are:

Welding current.
Current type and polarity.
Travel speed.
Shape of tungsten electrode tip and vertex angle.
Shielding gas flow rate.
Electrode extension.

Each of these is considered in more detail in the following sub-sections.

12.2.1 Welding current

Weld penetration is directly related to welding current.
If the welding current is too low, the electrode tip will not be properly heated and
an unstable arc may result.
If the welding current is too high, the electrode tip might overheat and melt,
leading to tungsten inclusions.

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12.2.2 Current type and polarity
Best welding results are usually obtained with DC-ve.
Refractory oxides such as those of aluminium or magnesium can hinder fusion
but can be removed by using AC or DC electrode positive.
With a DC positively connected electrode, heat is concentrated at the electrode
tip so the electrode needs to be of greater diameter than when using DC-ve if
overheating of the tungsten is to be avoided. A water cooled torch is
recommended if DC positive is used.
The current carrying capacity of a DC positive electrode is about one tenth that
of a negative one so it is limited to welding sections.

- +

Ions Electrons Ions Electrons Ions Electrons

(A.C.)

Figure 12.2 Effect of current type and polarity.

Table 12.1 Current type and polarity.

Current DC-ve AC DC+ve
type/polarity

Heat balance 70% at work 50% at work 30% at work

30% at electrode 50% at electrode 70% at electrode

Weld profile Deep, narrow Medium Shallow, wide

Cleaning action No Yes every half cycle Yes

Electrode Excellent Good Poor

capacity (3.2mm/400A) (3.2mm/225A) (6.4mm/120A)

12.2.3 Travel speed

Affects both weld width and penetration but the effect on width is more
pronounced.
Increasing the travel speed reduces the penetration and width.
Reducing the travel speed increases the penetration and width.

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12.2.4 Tungsten electrode types
Different types of tungsten electrodes suit different applications:

Pure tungsten electrodes are used when welding light metals with AC because
they maintain a clean balled end, but possess poor arc initiation and stability in
AC mode compared with other types.
Thoriated electrodes are alloyed with thorium oxide (thoria) to improve arc
initiation and have higher current carrying capacity than pure tungsten
electrodes and maintain a sharp tip for longer. Unfortunately, thoria is slightly
radioactive (emitting radiation) and the dust generated during tip grinding
should not be inhaled. Electrode grinding machines used for thoriated tungsten
grinding should be fitted with a dust extraction system.
Ceriated and lanthaniated electrodes are alloyed with cerium and lanthanum
oxides, for the same reason as thoriated electrodes and operate successfully
with DC or AC and as cerium and lanthanum are not radioactive, they have been
used as replacements for thoriated electrodes.
Zirconiated electrodes are alloyed with zirconium oxide with operating
characteristics between the thoriated types and pure tungsten. They are able to
retain a balled end during welding, so are recommended for AC welding. They
have a high resistance to contamination so are used for high integrity welds
where tungsten inclusions must be avoided.

12.2.5 Shape of tungsten electrode tip

With DC-ve, thoriated, ceriated or lanthanated tungsten electrodes are used with
the end ground to a specific angle (the electrode tip or vertex angle, shown
below).
As a general rule the length of the ground portion of the electrode tip should
have a length equal to approximately 2-2.5 times the electrode diameter. When
using AC the electrode tip is ground flat to minimise the risk of it breaking off
when the arc is initiated or during welding (shown on the next page).

If the vertex angle is increased, the penetration increases.

If the vertex angle is decreased, bead width increases.
Pure or zirconiated tungsten electrodes are used for AC welding with a
hemispherical (balled) end (as shown below). To produce a balled end the
electrode is ground, an arc initiated and the current increased until it melts the
tip of the electrode.

Electrode tip Electrode tip Electrode tip with

(or vertex angle) with flat end a balled end

Figure 12.3 Examples of tungsten electrode tip shapes.

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12.2.6 Shielding gases
The following inert gases can be used as shielding gases for TIG welding:

Argon.
Helium.
Mixtures of argon and helium.

Note : For austenitic stainless steels and some cupro-nickel alloys, argon with up to
~5% hydrogen improves penetration and reduces porosity.

Table 12.2 Characteristics of argon and helium shielding gases for TIG welding.
Argon Performance Helium
item

Lower than with helium
which can be helpful when
welding thin sections. Less
change in arc voltage with
variations in arc length.
Arc voltage Higher than with argon. Arc is
hotter which is helpful in welding
thick sections and viscous
metals, (eg nickel.

Lower than with helium Heating power High, advantageous when

which gives reduced of the arc welding metals with high thermal
penetration. conductivity and thick materials.

Argon is heavier than air so
requires less gas to shield
in the flat and horizontal
positions. Better draught
resistance.
Protection Helium is lighter than air and
of weld requires more gas to properly
shield the weld. Exception:
Overhead welding.

Obtained from the Availability Obtained by separation from

atmosphere by the and cost natural gas lower availability
separation of liquefied air and higher cost.
lower cost and greater
availability.

Shielding gas flow rate

Too low and the shielding gas cannot remove the air from the weld area
resulting in porosity and contamination.
Too high and turbulence occurs at the base of the shielding gas column, air
tends to be sucked in from the surrounding atmosphere and this may also lead
to porosity and contamination.
Typically in the range ~10-~12 l/min.

Flow rate too low Flow rate too high

Figure 12.4 Shielding gas flow rate.

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 Back purging
It is necessary to protect the back of the weld from excessive oxidation during TIG
welding, achieved by using a purge gas, usually pure argon.

For pipe welding spools it is relatively easy to purge the pipe bore, but for
plate/sheet welding it is necessary to use a purge channel or sometimes another
operator positions and moves a back purge nozzle as the weld progresses. For
purging large systems soluble dams or bungs are required and can it can be a
complex operation.

The initial stage of back purging is to exclude all the air at the back of the weld and
having allowed sufficient time for this the flow rate should be reduced prior to
starting to weld so there is positive flow (typically ~4 l/min).

Back purging should continue until two or more layers of weld have been deposited.

For C and C-Mn steels it is possible to make satisfactory welds without a back
purge.

12.2.7 Electrode extension

The distance from the contact tube to the tungsten tip.
Because the contact tube is recessed inside the gas nozzle this parameter can
be checked indirectly by measuring the stickout length, as shown below.

Electrode
Stickout extension

Figure 12.5 Electrode extension.

If the electrode extension is too short, the electrode tip will not be adequately
heated leading to an unstable arc.
If the electrode extension is too long, the electrode tip might overheat, causing
melting and lead to tungsten inclusions.
As a general rule stickout length should be 2-3 times the electrode diameter.

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12.3 Filler wires
Filler wires usually have a similar composition to the parent metal but contain small
additions of elements that will combine with any oxygen and nitrogen present.

12.4 Tungsten inclusions

Small fragments of tungsten that enter a weld will always show up on radiographs
because of the relatively high density of this metal and for most applications will not
be acceptable.

Thermal shock to the tungsten causing small fragments to enter the weld pool is a
common cause of tungsten inclusions and is why modern power sources have a
current slope-up device to minimise this risk.

This device allows the current to rise to the set value over a short period so the
tungsten is heated more slowly and gently.

12.5 Crater cracking

One form of solidification cracking which some filler metals are sensitive to. Modern
power sources have a current slope-out device so that at the end of a weld when the
welder switches off the current it reduces gradually and the weld pool gets smaller
and shallower. The weld pool will have a more favourable shape when it finally
solidifies and crater cracking can be avoided.

12.6 Common applications

Include autogenous welding of longitudinal seams in thin walled pipes and tubes in
stainless steel and other alloys on continuous forming mills.

Using filler wires, TIG is used for making high quality joints in heavier gauge pipe
and tubing for the chemical, petroleum and power generating industries.

It is also used in the aerospace industry for items such as airframes and rocket
motor cases.

12.7 Advantages
Produces superior quality welds with very low levels of diffusible hydrogen so
there is less danger of cold cracking.
No weld spatter or slag inclusions which makes it particularly suitable for
applications that require a high degree of cleanliness, eg pipework for the food
and drinks industry, manufacturing semiconductors, etc.
Can be used with filler metal and on thin sections without filler and can
produces welds at relatively high speed.
Enables welding variables to be accurately controlled and is particularly good
for controlling weld root penetration in all welding.
Can weld almost all weldable metals including dissimilar joints but welding in
position is not generally used for those with low melting points such as lead and
tin. Especially useful in welding reactive metals with very stable oxides such as
aluminium, magnesium, titanium and zirconium.
The heat source and filler metal additions are controlled independently so it is
very good for joining thin base metals.

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12.8 Disadvantages
Gives low deposition rates compared with other arc welding processes. Need
higher dexterity and welder co-ordination than with MIG/MAG or MMA welding.

Less economical than MMA or MIG/MAG for sections thicker than ~10mm.
Difficult to fully shield the weld zone in draughty conditions so may not be
suitable for site/field welding.
Tungsten inclusions can occur if the electrode contacts the weld pool.
No cleaning action so low tolerance for contaminants on filler or base metals.

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