1.

INTRODUCTION
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.
Tungsten Inert Gas (TIG) welding uses the heat generated by an electric arc struck between
a non-consumable tungsten electrode and the work piece to fuse metal in the joint area and
produce a molten weld pool. The arc area is shrouded in an inert or reducing gas shield to protect
the weld pool and the non-consumable electrode. The process may be operated autogenously,
that is, without filler, or filler may be added by feeding a consumable wire or rod into the
established weld pool. TIG produces very high quality welds across a wide range of materials
with thicknesses up to about 8 or 10mm. It is particularly well suited to sheet material.
The commonly used electrodes in TIG are pure tungsten, zirconated tungsten and
thoriated tungsten. Thorium or zirconium are added to improve the thermoionic emmisions.An
inert gas generally, helium or argon is used for shielding. Filler metal may or not be used
depending upon the the thickness of the pieces to be joined, flux is not used. Therefore,
negligible post weld cleaning is required due to gas shielding. The weld produced are strong,
ductile and corrosion resistant. Nearly all commercial metals can be welded using TIG for
example like Aluminium and its alloy, Magnesium alloy, Nickel based alloy, Copper based
alloys, low alloy steel, Carbon steels and stainless steels.
A wide variety of joineds can be produced however commonly used ones are square butt
joint, single V bevel and double V-bevel. This process can be used for joining dissimilar metals,
hard facing and surfacing of metals. The tip of the gun in this process needs to be made of high
impact ceramic or water cooled. A constant-current welding power supply produces energy
which is conducted across the arc through a column of highly ionized gas and metal vapors
known as a plasma. A constant-current welding power supply produces energy which is
conducted across the arc through a column of highly ionized gas and metal vapors known as a
plasma.
TIG is most commonly used to weld thin sections of stainless steel and nonferrous metals
such as aluminum, magnesium, andcopper alloys. The process grants the operator greater control
over the weld than competing processes such as shielded metal arc welding and gas metal arc
welding, allowing for stronger, higher quality welds. However, TIG is comparatively more
complex and difficult to master, and furthermore, it is significantly slower than most other
welding techniques. A related process,plasma arc welding, uses a slightly different welding torch
to create a more focused welding arc and as a result is often automated.

2.0 MACHINE AND MATERIAL SELECTION

Tungsten electrodes

Flow meter regulator

Weldmark tungsten

TIG welding rods

TIG welding torch

TIG welding torch back caps

AC DC Tig stick welder

Gloves

Lab coat

Safety shoes

Helmet

3.0 PROCESS FLOW

Safety first

Cooling and post

weld cleaning

Select joint
design and fit up

Determine the
appropriate inert
shielding gas

Welding
technique

Select the
applicable filler
metal

Clean the base

metal

Set the
parameters

4.0 PROCEDURE

1.

Safety first. Read and understand the manufacturer's instructions. Keep your head out of
the fumes. Wear correct eye, ear, & body protection. Do not touch live electrical parts.

2.

Select joint design and fit up. Start by determining the best manner in which to join your
base metals. Correct joint design & fit up are critical steps to insuring a strong bond upon
weld completion. Be sure to consider strength required, welding position, metal thickness
and joint accessibility.

3.

Determine the appropriate inert shielding gas. Argon is suggested for thicknesses up to
approximately inch. For thicker sections, argon-helium mixtures or pure helium may
be used. Pure helium may also be employed for deeper penetration.

4.

Select the applicable filler metal. For applications where both pieces are the same alloy,
select filler metal with a composition similar to that of the base metals. This will ensure
the weld has similar properties. Dissimilar base metal applications require selection based
on mechanical properties, freedom from cracking, and compatibility.

5.

Set the parameters. For gas tungsten arc welding use DC current with straight polarity
which is electrode negative. The parameters for TIG welding are dependent upon plate
thickness and welding position.

6.

Clean the base metal. Cleaning should be done just prior to welding to prevent the
formation of oxides. The base metal surface must be free of grease, oil, paint, dirt, etc. A
clean surface will provide a smoother, stronger joint. Brush the plate surface & edges
with a stainless steel wire brush to remove burrs & oxides. Gloves should be worn to
prevent hand oil or dirt from getting on the joining surface.

7.

Welding technique. Use fixtures &/or jigs to help keep work in place. Insure adequate
shielding by centering the filler metal in the gas & weld puddle area. Filler metal should
be dipped into the weld puddle, but should not drip into it. Move the torch along the joint
at a steady, constant speed to maintain uniformity. Hold the torch/gun over the weld until
gas stops, to keep work protected.

8.

Cooling and post weld cleaning. Post-heat may be required to relieve internal stresses
caused by the concentration of heat in the weld area. Post-heating aids in slow down of
the cooling process to minimize cracking. This is a good procedure to use when joining
thick metals. Remove slag with a chipping hammer or by grinding.