TIG Welding

Introduction

Outline
Background/Advantages

& Disadvantages

Safety
Preparation

for TIG Welding

Techniques for Basic Weld Joints
TIG Shielding Gases
Welding Parameters
Tungsten Electrode Selection
Conclusion
2

Conclusion

TIG welding is an exciting skill that proves itself

useful in countless applications
Because it welds more metal and metal alloys than
any other process, TIG welding should be regarded
as an important tool where experience is the teacher
Welding parameters and tungsten electrode
selection tables are recommended values and
should be used as a guideline
Information presented here is only the tip of the
iceberg, and further research and hands-on
involvement should be pursued to be comprehensive

Background
What

is TIG?

Tungsten Inert Gas

Also

referred to as GTAW

Gas Shielded Tungsten Welding

In

TIG welding, a tungsten electrode

heats the metal you are welding and
gas (most typically Argon) protects the
weld from airborne contaminants
4

Background
TIG

welding uses a non-consumable

tungsten
Filler metal, when required, is added
by hand
Shielding gas protects the weld and
tungsten

Advantages
Welds

more metals
and metal alloys than
any other process
High quality and
precision
Pin point control
Aesthetic weld beads
No sparks or spatter
No flux or slag
No smoke or fumes
6

Disadvantages

Lower filler metal

deposition rates
Good hand-eye
coordination a required
skill
Brighter UV rays than
other processes
Slower travel speeds
than other processes
Equipment costs tend
to be higher than other
processes
7

Safety
Electric

shock can kill.

Always wear dry insulating gloves

Insulate yourself from work and ground
Do not touch live electrical parts
Keep all panels and covers securely in place

Fumes

health.

and gases can be hazardous to your

Keep your head out of the fumes

Ventilate area, or use breathing device
8

Safety
Welding

can cause fire or explosion.

Do not weld near flammable material

Watch for fire; keep extinguisher nearby
Do not locate unit over combustible surfaces
Do not weld on closed containers

Arc

rays can burn eyes and skin; Noise

can damage hearing.
Wear welding helmet with correct shade of
filter
Wear correct eye, ear, and body protection
9

Safety
Hot

parts can cause injury.

Allow cooling period before touching welded

metal
Wear protective gloves and clothing
Magnetic

fields from high currents can

affect pacemaker operation.
Flying metal can injure eyes.
Welding, chipping, wire brushing, and
grinding cause sparks and flying metal; wear
approved safety glasses with side shields
10

Safety
Welding

current can damage electronic parts

in vehicles.
Disconnect both battery cables before welding on
a vehicle
Place work clamp as close to the weld as possible

11

Techniques for Basic Weld

Joints
Arc Length
Arc

length normally one electrode diameter,

when AC welding with a balled end electrode
When DC welding with a pointed electrode,
arc length may be much less than electrode
diameter

12
*Figure copied from TIG Handbook

Techniques for Basic Weld

Joints
Gas Cup Size
Inside

diameter of gas
cup should be at least
three times the
tungsten diameter to
provide adequate
shielding gas
coverage
Picture on right shows
example of gas cup
size and torch position
1-Workpiece, 2-Work clamp, 3-Torch, 4-Filler
rod, 5-Gas cup, 6-Tungsten electrode
*Figure copied from TIG Handbook

13

Techniques for Basic Weld

Joints
Electrode Extension
Refers

to distance the tungsten extends out

beyond the gas cup
May vary from flush with the gas cup to no
more than the inside diameter of the gas cup
Longer the extension, the more likely it may
contact something by accident
General rule would be to start with an
extension of one electrode diameter
14

Techniques for Basic Weld

Joints
Arc Starting with High
Frequency
Torch position on left shows
recommended method of
starting the arc with high
frequency when the torch is held
manually
By resting gas cup on base
metal there is little danger of
touching the electrode to the
work
After arc is initiated, torch can be
raised to proper welding angle15

*Figure copied from TIG Handbook

Techniques for Basic Weld

Joints
Manual Torch Movement

ENBE 499
*Figure copied from TIG Handbook

16

Techniques for Basic Weld

Joints
Manual Torch Movement
Torch

and filler rod must be moved

progressively and smoothly so the weld pool,
the hot filler rod end, and the solidifying weld
are not exposed to air that will contaminate
the weld metal area or heat affected zone
When arc is turned off, postflow of shielding
gas should shield the weld pool, electrode,
and hot end of the filler rod
17

Techniques for Basic Weld

Joints
Butt Weld and
Stringer Bead
Be

sure to center
weld pool on
adjoining edges
When finishing a butt
weld, torch angle
may be decreased to
aid in filling the crater
Torch and rod position for welding the butt weld and
stringer bead
18
*Figure copied from TIG Handbook

Techniques for Basic Weld

Joints
Lap Joint

Pool is formed so that the

edge of the overlapping
piece and the flat surface
of the second piece flow
together
Torch angle is important
because the edge will
become molten before
the flat surface
Enough filler metal must
be added to fill the joint
as illustrated on the right
Torch and rod position for welding the lap
joint

*Figure copied from TIG Handbook

19

Techniques for Basic Weld

Joints
T-Joint

Edge will heat up and

melt sooner
Torch angle illustrated
will direct more heat
onto the flat surface
Electrode may need to
be extended further
beyond the cup in order
to hold a short arc
Torch and rod position for welding the T-joint
20

*Figure copied from TIG Handbook

Techniques for Basic Weld

Joints
Corner Joint
Both

edges of the
adjoining pieces
should be melted
and the pool kept on
the joint centerline
Sufficient filler metal
is necessary to
create a convex bead
as shown

Torch and rod position for welding the corner joint

21

*Figure copied from TIG Handbook

TIG Shielding Gases

Argon
Helium
Argon/Helium

Mixtures

22

TIG Shielding Gases

Argon

Good arc starting

Good cleaning action
Good arc stability
Focused arc cone
Lower arc voltages
10-30 CFH flow rates

Helium

Faster travel speeds

Increased penetration
Difficult arc starting
Less cleaning action
Less low amp stability
Flared arc cone
Higher arc voltages
Higher flow rates (2x)
Higher cost than argon
23

TIG Shielding Gases

Argon/Helium Mixtures

Improved travel speeds over pure argon

Improved penetration over pure argon
Cleaning properties closer to pure argon
Improved arc starting over pure helium
Improved arc stability over pure helium
Arc cone shape more focused than pure helium
Arc voltages between pure argon and pure helium
Higher flow rates than pure argon
Costs higher than pure argon
24

Welding Parameters

Aluminum weld parameters

25
*Figure copied from TIG Handbook

Welding Parameters

Aluminum with advanced squarewave weld parameters

26
*Figure copied from TIG Handbook

Welding Parameters

Stainless steel weld parameters

27
*Figure copied from TIG Handbook

Welding Parameters

Titanium weld parameters

28
*Figure copied from TIG Handbook

Welding Parameters

Mild steel weld parameters

29
*Figure copied from TIG Handbook

Tungsten Electrode Selection

Guide to selecting a tungsten electrode based on amperage range

30
*Figure copied from Guidelines to Gas Tungsten Arc Welding (GTAW)