Journal of Materials Processing Technology 89±90 (1999) 410±414

TIG pulse welding of 304L austenitic stainless

steel in ¯at, vertical and overhead positions
G. Lothongkuma,*, P. Chaumbaib, P. Bhandhubanyonga
a
Department of Metallurgical Engineering, Faculty of Engineering, Chulalongkorn University, Bangkok 10330, Thailand
b
Volvo Thailand Ltd., Bangkok, Thailand

Abstract

The TIG pulse welding parameters of 304L stainless steel sheet of 3 mm thickness in ¯at, vertical and overhead positions were
investigated. The shielding gases were Ar, and Ar‡N2 (0±5%, v/v). The base and pulse currents in all welding positions were adjusted to
achieve a weld bead contour corresponding to DIN 8563 class AS at 3.4 mm/s welding speed, 1 pulse/s pulse frequency and 55% on-time.
The weld bead aspect ratios (W/D) are 2.7±2.8. Increasing welding speed to 5 and 6.8 mm/s whilst simultaneously increasing the pulse
frequency, the base and pulse currents, at constant 55% on-time was not successful in achieving weld bead contours to satisfy DIN 8563. In
the vertical and overhead positions, gravitational force made the weld pool fall down, leading to undercut after solidi®cation. With the
appropriate welding parameters, the gravitational effect can be eliminated. The d-ferrite content in the weld metals was in the acceptable
range (3±12%, v/v) when the nitrogen content in the Ar shielding gas was between 3±5%, v/v. # 1999 Elsevier Science S.A. All rights
reserved.

Keywords: TIG pulse welding; Stainless steel; Weld bead

1. Introduction 2. Experimental

Austenitic stainless steels are used widely in Thailand's
industries. It is estimated that the 304, 304L, 316L austenitic
stainless steels are used to the extent of more than 20 000
tons a year [1,2]. In many cases, those stainless steels must
be welded, for example, the welding of stainless steel pipe,
the welding of automotive exhaust gas systems, welding
repair of chemical industrial equipment, etc., TIG pulse
welding is one of the generally applied methods. The
TIG pulse welding parameters for especially vertical and
overhead positions are not well known in Thailand. In this
work the parameters of TIG pulse welding such as speed,
base and pulse currents, pulse frequency, % on-time (the
pulse current time in one cycle) and shielding gas composi-
tion were investigated. Excessive penetration of the weld
bead pro®le is kept to follow DIN 8563 [3], as shown in
Fig. 1. Other weld bead requirements are also kept to satisfy
DIN 8563. Nitrogen was added in the Ar shielding gas to
control the d-ferrite content in the weld metal to be in the
recommended range of 3±12%, v/v [4,5] to avoid hot
cracking and toughness reduction of the weld metal.
*Corresponding author. E-mail: lgobboon@chula.ac.th
Fig. 2 is the ¯ow line diagram of the shielding gas.
Nitrogen (99.99%) was mixed to argon (99.995%) through
a mixer M1. The mixed gas after the mixer M1 was split to
¯ow in the root shielding gas line with rate of 8 l/min and
¯ow in the arc shielding gas line with rate of 16 l/min. The %
on-time nitrogen content in the argon shielding gas was
calculated in volume percentage from the ¯ow rate read out
from the manometers F1 and F2.
The chemical composition of the 304L stainless steel
sheet of 3 mm in thickness used in these experiments is
shown in Table 1. An all-round turnable welding table, self
assembled, with a speed controller was used for adjusting
the welding positions and the welding speed. The welding
machine was of constant current AC/DC type. Samples of
sizes of 100 mm125 mm3 mm with square-edge but
joints were prepared from stock plate, installed on the
welding table and welded with the planned parameters such
as welding speed, base and pulse current, de®ned as in
Fig. 2. Welding currents were measured by using a data
logger hydra acquisition series. Preliminary welding tests
were done in the ¯at position to see the effects of welding
speed, pulse frequency, % on-time, and base current on the

0924-0136/99/$ ± see front matter # 1999 Elsevier Science S.A. All rights reserved.
PII: S 0 9 2 4 - 0 1 3 6 ( 9 9 ) 0 0 0 4 6 - 1
 G. Lothongkum et al. / Journal of Materials Processing Technology 89±90 (1999) 410±414
Fig. 1. Excessive penetration according to DIN 8563 (3).
Fig. 2. Line diagram of the gas flow and the base and pulse currents
generated by the welding machine in the present experiments.
weld bead contour according to DIN 8563. Then the opti-
mum values of the welding parameters such as welding
speed, pulse frequency, % on-time, base and pulse current,
and nitrogen content in the argon shielding gas in ¯at,
vertical and overhead positions were determined by starting
from the successful parameters in the preliminary welding
test in ¯at position. The accepted weld bead samples were
examined by radiographic tests for porosity and prepared for
metallographic observation and study. Only weld metal was
machined to small pieces for the analysis of the nitrogen
contents by a nitrogen determinator. The weld metal d-ferrite
contents were calculated using the quantitative metallogra-
phy method [6].
3. Results and discussion
3.1. Preliminary test results of welding in flat position
The effects of welding speed, pulse frequency, % on-time,
and base current on the weld bead contour in the ¯at position
using pure argon as shielding gas were examined. The test
results are summarized in Table 2. Runs 1±10 were pre-
Table 1
Chemical composition (wt%) of 304L stainless steel analyzed by emission spectroscopy
C Si Mn P S
0.0305 0.461 1.270 0.047 0.013
411
experiments to ®nd the parameters giving a weld bead
contour according to DIN 8563. Further experimental results
to investigate the effects of welding speed, pulse frequency,
% on-time, and base current shown in runs 11±30. The
results in Table 2 showed that only limited ranges of these
welding parameters are acceptable. The best parameters
observed in this section were in run 27. These parameters
were nearly the same as those introduced in the work of
Kujanpaa [7], which suggested a welding speed of 3.3 mm/s
and a welding current of 185 A for ordinary TIG welding.
This result implied that to be successful in the TIG pulse
welding of the 304L stainless steel, the parameters, which
are not exclusively independent, should be in good combi-
nation.
3.2. Welding parameters in flat, vertical and overhead
positions
In this section, the welding speed, pulse frequency, nitro-
gen content in argon shielding gas, pulse current and base
current at each welding position were examined, whilst the
% on-time was kept constant at 55% in all test runs.
Three different welding speeds of 3.4, 5, 6.8 mm/s were
tested. According to the result in Section 3.1, the pulse
frequency, pulse currents and base currents will be changed
in relation to the welding speed, the pulse frequency, pulse
currents and base currents being increased with the welding
speed in order to secure similar weld bead pro®les and
surfaces to those in the case of lower welding speeds. Thus
the appropriate pulse frequencies at welding speeds of 3.4, 5
and 6.8 mm/s are 1, 1.5±2, and 2 pulse/s, respectively.
Summary results of welding with these parameters are
shown in Figs. 3±5.
In Figs. 3±5, at welding speeds of 5 and 6.8 mm/s, all
weld runs were with a nitrogen content of 0±3%, v/v. in
argon shielding gas. It can be clearly seen that pulse
frequencies of 1.5±2 pulse/s, base currents of 70±105 A,
and pulse currents of 200±312 A, are not acceptable. Defects
such as undercuts, not enough penetration, not a smooth
rippled surface, a concave surface appearance, too long a
distance between the peaks of the ripple, occurred. Fig. 6
shows an example of the weld bead pro®le and surface
appearance of metal welding in the ¯at position with a
nitrogen content of 1%, v/v. in argon shielding gas, a
welding speed of 3.4 mm/s, a base current of 48 A, a pulse
current of 185 A, 55% on-time, and a pulse frequency of 1
pulse/s. A rippled surface of the weld bead is clearly seen,
which is the effect of pulse frequency. An example of the
weld defects found is shown in Fig. 7.
Ni Cr Fe N Others
9.42 18.71 69.24 0.01 0.810
412 G. Lothongkum et al. / Journal of Materials Processing Technology 89±90 (1999) 410±414

Table 2
Preliminary test welding results in the flat position with pure argon shielding gas

Run Pulse frequency, Speed, Pulse current, Base current, Percent Uˆunaccepted,
f (pulse/s) Vw (mm/s) Ip (A) Ib (A) on-time Aˆaccepted
(DIN 8563)

1 0.75 4.0 144 91 55 U

2 0.75 4.0 156 91 55 U
3 0.75 4.0 160 100 55 U
4 0.75 4.0 160 100 55 U
5 1.0 4.0 185 77 55 U
6 1.0 3.4 190 35 55 U
7 1.0 3.4 190 42 55 U
8 1.0 3.4 190 38 55 U
9 1.0 3.4 190 42 55 U
10 1.0 3.4 190 42 55 A
11 1.0 3.0 200 42 55 U
12 1.0 3.4 200 42 55 A
13 1.0 3.8 200 42 55 U
14 1.0 5.0 200 42 55 U
15 1.0 6.8 200 42 55 U
16 0.4 3.4 200 42 55 U
17 0.5 3.4 200 42 55 U
18 1.0 3.4 200 42 55 A
19 1.5 3.4 200 42 55 U
20 2.0 3.4 200 42 55 U
21 1.0 3.4 200 42 35 U
22 1.0 3.4 200 42 45 U
23 1.0 3.4 200 42 55 A
24 1.0 3.4 200 42 65 U
25 1.0 3.4 200 26 55 U
26 1.0 3.4 200 35 55 U
27 1.0 3.4 200 42 55 A
28 1.0 3.4 200 52 55 U
29 1.0 3.4 200 61 55 U
30 1.0 3.4 200 70 55 U

Fig. 3. Base (&) and pulse (}) currents at welding speeds of 3.4, 5, and Fig. 4. Base (&) and pulse (}) currents at welding speeds of 3.4, 5 and
6.8 mm/s, and pulse frequencies of 1, 1.5±2, and 2 pulse/s, respectively, 6.8 mm/s, pulse frequencies of 1, 1.5±2, and 2 pulse/s, respectively, with
with the flat welding position, 55% on-time, and Ar‡N2 (0±3%). the vertical welding position, 55% on-time, and Ar‡N2 (0±3%).
 G. Lothongkum et al. / Journal of Materials Processing Technology 89±90 (1999) 410±414
Fig. 5. Base (&) and pulse (}) currents at welding speeds of 3.4, 5 and
6.8 mm/s, pulse frequencies of 1, 1.5±2, and 2 pulse/s, respectively, with
the overhead welding position, 55% on-time, and Ar‡N2 (0±3%).
The acceptable parameters were obtained only at a weld-
ing speed of 3.4 mm/s in all cases of nitrogen contents in
argon shielding gas with a pulse frequency of 1 pulse/s, base
currents of 42±48 A, and pulse currents of 185±200 A, for
all welding positions. Fig. 8 shows acceptable base and
pulse currents in the ¯at, vertical and overhead positions
with a nitrogen content of 0±3%, v/v., a welding speed of
3.4 mm/s, pulse frequency of 1 pulse/s, and 55% on-time.
Table 3 summaries the appropriate TIG pulse welding
parameters for the 304L stainless steel with the ¯at, vertical
and overhead positions, a welding speed of 3.4 mm/s, a pulse
frequency of 1 pulse/s, % on-time of 55%, a root shielding
gas ¯ow rate of 8 l/min, and a shielding gas ¯ow rate of 16 l/
min. This table shows very narrow possible welding para-
Fig. 6. The weld bead profile and appearance in the TIG pulse welding of
304L stainless steel in the flat position, with pure Ar as the shielding gas, a
welding speed 3.4 mm/s, a base current 48 A, a pulse current 185 A, a 55%
on-time, and a pulse frequency of 1 pulse/s.
413
Fig. 7. Example of weld defects after flat position welding with a welding
speed of 6.8 mm/s, a pulse frequency of 2 pulse/s, a pulse current of 312 A,
a base current of 105 A, and 55% on-time.
meter ranges. Similar welding parameters for duplex stain-
less steel pipes were obtained in the work of Huismann and
Hoffmeister [8] with welding speed of 4 mm/s and pulse
currents of 250±350 A.
3.3. Microstructure
Metallographic examination and nitrogen content deter-
mination were done with acceptable weld beads obtained
from welding with the parameters shown in Table 3.
The amount of nitrogen in the weld metal at various
nitrogen contents in the argon shielding gas is shown in
Fig. 9. Pure argon shielding gas in this TIG pulse welding
did not totally shield the weld pool from air. A higher
nitrogen content in weld metal welding with pure argon
shielding gas than the content in the base metal was
observed. The weld metal nitrogen content increased from
0.06 to 0.15 wt% as the nitrogen content in the argon
shielding gas was increased from 0 to 5% (v/v.). (Additional
data of welding with 4 and 5% (v/v.) nitrogen content in
argon shielding gas was obtained for con®rmation of the
Fig. 8. Appropriate pulse and base currents for the flat (6 h), vertical (9 h),
and overhead (12 h) positions with various nitrogen content in argon
shielding, a welding speed of 3.4 mm/s, a pulse frequency of 1 pulse/s, and
55% on-time.
414 G. Lothongkum et al. / Journal of Materials Processing Technology 89±90 (1999) 410±414

Table 3
Appropriate accepted parameters at a welding speed of 3.4 mm/s in the flat, vertical and overhead positions

Position with %N2 in Ar (v/v)

Flat Vertical Overhead

0 1 2 3 0 1 2 3 0 1 2 3

Base current (A) 42 42 48 48 42 42 42 48 42 42 42 42

Pulse current (A) 200 190 185 190 197 195 195 190 197 190 190 190

results.) Similar results were obtained in the work of

Kuwana and his coworkers [9], which showed higher nitro-
gen contents in the weld metal than those in this work. This
is because of the use of lower welding currents in their work
than those in the present work, which caused a decrease in
the nitrogen content in the weld metal. The reason for the
decrease in the nitrogen content with increase in the welding
current is still not clear. [9] Fig. 10 shows the amount of d-
ferrite content with the nitrogen content in the weld metal.
As can be seen in this ®gure, the d-ferrite content in the weld
metal is in the acceptable range (3±12%), whilst the nitrogen
contents in the weld metal is 0.13±0.15 wt% corresponding
to a nitrogen content in the argon shielding gas of 3±5%, v/v.

4. Conclusion

Appropriate TIG pulse welding parameters for 304L
stainless steel in the ¯at, vertical and overhead positions
with a nitrogen content of 0±3% (v/v.) in the argon shielding
gas were established. The welding speeds in those positions
were limited to 3.4 mm/s at 55% on-time with appropriately
adjusted pulse and base currents. To gain a higher welding
rate by increasing the welding speeds to more than 3.4 mm/s
Fig. 10. The d-ferrite content and nitrogen content in the weld metal.
simultaneously with increasing pulse frequencies, pulse
currents and base currents, was not successful. A nitrogen
content of 3±5% (v/v.) in the argon shielding gas was enough
to control the d-ferrite contents in the generally accepted
range of 3±12% (v/v.).

References

[1] TGPRO, Thailand, unpublished.

[2] THAINOX, Thailand, unpublished.
[3] Quality Assurance of Welding Operation, DIN 8563 part 3 (Oct.
1985).
[4] R. Castro, J.J. de Cadenet, Welding Metallurgy of Stainless and Heat
resisting Steels, (Translated from the French by R.C. Jain),
Cambridge University Press, Cambridge, 1974.
[5] D.L. Olson, Prediction of austenitic weld metal micro-structure and
properties, Welding J. (Oct. 1985) 281-s±295-s.
[6] Quantitative Metallography, ASM Metal Handbook, vol. 9, 9th ed.,
1985 p. 129.
[7] V.P. Kujanpaa, Weld defects in austenitic stainless steel sheet-effect
of welding parameters, Welding J. (1983) 45-s±52-s.
[8] G. Huismann, H. Hoffmeister, Investigation of the effects of TIG
pulse parameters and shielding gas compositions on weld bead
formation and microstructure of Duplex stainless steel orbital TIG
root welds, LWS, University of the federal armed force, Hamburg,
Germany, 1992.
Fig. 9. The nitrogen content in the weld metal and in the argon shielding
[9] J.F. Lancaster, Metallurgy of Welding, 5th ed., 1993, p. 260.
gas.