LIST OF CONTENTS
History of TIG
Power Sources
TIG Overview
10
10
11
Connection Diagrams
12
13
Regulators
14
15
Shielding Gas
16
17
TIG Wires
20
20
21
Pulsed TIG
Guide for Shield Gas Flows, Current Settings and Cup Selection
Correct Torch and Rod Positioning
18
22
23
Personal Protection
24
25
OVERVIEW
TIG welding is a welding process that uses a power source, a shielding gas
and a TIG handpiece. The power is fed out of the power source, down the
TIG handpiece and is delivered to a tungsten electrode which is fitted into the
handpiece. An electric arc is then created between the tungsten electrode
and the workpiece. The tungsten and the welding zone is protected from
the surrounding air by a gas shield (inert gas). The electric arc can produce
temperatures of up to 19,400oC and this heat can be very focused local
heat.
The weldpool can be used to join the base metal with or without filler
material.
The TIG process has the advantages of 1) Narrow concentrated arc
2) Able to weld ferrous and non-ferrous metals
3) Does not use flux or leave a slag
4) Uses a shielding gas to protect the weldpool and tungsten
5) A TIG weld should have no spatter
6) TIG produces no fumes but can produce ozone
The TIG process is a highly controllable process that leaves a clean weld
which usually needs little or no finishing. TIG welding can be used for both
manual and automatic operations.
The TIG welding process is so good that it is wisely used in the so-called
high-tech industry applications such as
1) Nuclear industry
2) Aircraft
3) Food industry
4) Maintenance and repair work
5) Some manufacturing areas
POWER SOURCES
TIG welding power sources have come a long way from the basic transformer
types of power sources which were used with add-on units to enable the
power source to be used as a TIG unit, eg high frequency unit and/or DC
rectifying units,
The basics of TIG welding has almost remained the same, but the advent of
technology TIG welding power sources have made the TIG processes more
controllable and more portable in some cases.
The TIG power source uses main power connected to a suitable power for
the TIG process being used. This can be either AC or DC.
The one thing that all TIGs have in common is that they are CC (Constant
Current) type power sources. This means only output adjustment will control
the power source amps. The voltage will be up or down depending on the
resistance of the welding arc.
A TIG power source can be of the AC or DC type. The principle of electric
circuits will apply to only DC power sources. This means 70% of the heat is
always on the positive side. So when a DC power source is used whatever
is connected to the positive side will have 70% of the energy output (heat).
When using an AC power source, which has an output of a wave form, the
average on both terminals will be the same. This is because for one half
of the wave form (cycle) the positive terminal will have 70% of the energy,
but as the wave form moves to the other half of the cycle it will move to the
negative terminal, which will then have the 70% of the energy.
Other things to check on TIG power sources are 1) Amperage to do the job. Will it be sufficient?
2) Does the amperage go low enough for light material and high enough
for thick material?
3) Power Supply - 400 Volt, 230 Volt - single or three phase. Is there
enough main power to do the job?
4) Is weight a problem? If so, is the inverter type power source more
suitable.
5) Will an engine driven power source be better to do the job? (Must
have CC range). Might need suitable extra add-ons to do the eg, HF
unit.
6) Would a multi-process type power source be better to do the job?
Must have CC range.
7) Does the TIG welding need an AC power source or DC power source,
as different material will need a different power type.
Once the welding current gets above a certain amperage (often depends on
the machine) the HF can be turned off, allowing the welding to be carried on
with the HF interfering with anything in the surrounding area.
CURRENT TYPE
DCSP
Electrode Polarity
Electrode Negative
No
Penetration Profile
Deep, narrow
Electrode Capacity
Excellent
DC TIG
POWER
SUPPLY
TIG welding with DCSP (direct current straight polarity) produces deep
penetration because it concentrates the heat in the joint area. No cleaning
action occurs with this polarity.
DC TIG
POWER
SUPPLY
CURRENT TYPE
DCRP
Electrode Polarity
Electrode Positive
Yes
Penetration Profile
Shallow, wide
Electrode Capacity
Poor
TIG welding with DCRP (direct current reverse polarity) produces good
cleaning action as the argon ions flowing towards the work strike with
sufficient force to break up oxides on the surface.
AC TIG
POWER
SUPPLY
CURRENT TYPE
ACHF
Electrode Polarity
Alternating
Penetration Profile
Medium
Electrode Capacity
Good
3) Nozzles - The nozzles job is to direct the correct gas flow over the
weldpool. (Please see Selecting the Correct Torch Nozzle, page 10.)
4) Back Caps - The back cap is the storage area for excess tungsten.
They can come in different lengths depending on the space the torch
may have to get into (eg. long, medium and short caps).
Please make sure when ordering a TIG torch to tell the supplier the amperage
rating, whether water- or air-cooled, and the fitting that is to go on the end of
the TIG torch lead suitable to fit the TIG power source it will be used from.
This may include power cable fit up, gas fittings and control plug fittings.
9
Exit
diameter
measured
in 1.6 mm
10
REGULATORS
The function of the gas regulator is to reduce bottle pressure gas down to
a lower pressure and deliver it at a constant flow. This constant flow of gas
flows down through the TIG torch lead to the TIG torch nozzle and around
the weldpool.
There are three main styles of regulator used for TIG
One made up with a single flow tube assembly (Fig. 1).
Another made up with a twin-flow tubes assembly (Fig. 3) (this set-up is
excellent for when purging is necessary).
The third style does not have a flow tube and the flow is set by turning
a handwheel (Fig. 2). The amount of gas flow needed to do the job will
depend on the welding job being done and the type of material being
welded. But a common setting to start with is 5 L/min.
Fig. 3
Fig. 1
Fig. 2
11
CONNECTION DIAGRAMS
Power
Source
Shield
gas
supply
TIG
Torch
Power Source
Water
out
Power cable
adaptor
required
Coolant
Recirculator
WATER IN
Shield
gas
supply
ARGON IN
Note: 1 litre per minute flow rate. Water in through water line. Water out
through power cable.
12
Thickness
Range
All
Desired
Results
General
Purpose
Welding
Electrode Type Shield Gas
Current
AC/HF
Aluminium
Alloys and
Magnesium Only thin
Alloys
sections
Control
penetration
Only
thick
sections
Increase
penetration
or travel
speed
Copper
Alloys,
DCRP
DCSP
and Nickel
Alloys
Titanium
Alloys
2% Thoriated
(EW-Th2)
75 Argon
25 Helium
2% Ceriated
(EW-Ce2)
Argon
Helium
2% Thoriated
(EW-Th2)
75 Argon
25 Helium
2% Ceriated
(EW-Ce2)
Helium
2% Thoriated
(EW-Th2)
75 Argon
25 Helium
2% Ceriated
(EW-Ce2)
75 Argon
25 Helium
Only thin
sections
Control
penetration
ACHF
Zirconiated
(EW-Zr)
Argon
Only
thick
sections
Increase
penetration
or travel
speed
DCSP
2% Ceriated
(EW-Ce2)
75 Argon
25 Helium
2% Thoriated
(EW-Th2)
75 Argon
25 Helium
2% Ceriated
(EW-Ce2)
75 Argon
25 Helium
2% Lanthanated
(EWG-La2)
75 Argon
25 Helium
Zirconiated
(EW-Zr)
Argon
2% Ceriated
(EW-Ce2)
75 Argon
25 Helium
2% Lanthanated
(EWG-La2)
Helium
All
General
Purpose
DCSP
Steels,
Steels and
Argon
DCSP
Carbon
Alloy
Zirconiated
(EW-Zr)
General
Purpose
Mild
Steels,
Argon
All
Cu-Ni
Alloys
Pure (EW-P)
Only thin
sections
Control
penetration
Only
thick
sections
Increase
penetration
or travel
speed
ACHF
DCSP
Tungsten Performance
Characteristics
Balls easily, low cost, tends to spit at
higher currents, used for non-critical
welds only.
Balls well, takes higher current, with
less spitting and with better arc starts
and arc stability than pure tungsten.
Higher current range and stability,
better arc starts, with lower tendency
to spit, medium erosion.
Lowest erosion rate, widest current
range, AC or DC, no spitting, best arc
starts and stability.
Best stability at medium currents,
good arc starts, medium tendency to
spit, medium erosion rate.
Low erosion rate, wide current range,
AC or DC, no spitting, consistent arc
starts, good stability.
Best stability at medium currents,
good arc starts, medium tendency to
spit, medium erosion rate.
Low erosion rate, wide current range,
AC or DC, no spitting, consistent arc
starts, good stability.
Use on lower currents only, spitting
on starts, rapid erosion rates at higher
currents.
Low erosion rate, wide current range,
AC or DC, no spitting, consistent arc
starts, good stability.
Best stability at medium currents,
good arc starts, medium tendency to
spit, medium erosion rate.
Low erosion rate, wide current range,
AC or DC, no spitting, consistent arc
starts, good stability.
Lowest erosion rate, wide current
range on DC, no spitting, best DC arc
starts and stability.
Use on lower currents only, spitting
on starts, rapid erosion rates at higher
currents.
Low erosion rate, wide current range,
no spitting, consistent arc starts, good
stability.
Lowest erosion rate, highest current
range, no spitting, best DC arc starts
and stability.
13
Alloying
Element
Colour*
Alloying
Oxide
Nominal Weight of
Alloying Oxide Percent
EWP
Green
EWCe-2
Orange
Cerium
CeO2
EWLa-1
Black
Lanthanum
La2O3
EWTh-1
Yellow
Thorium
ThO2
EWTh-2
Red
Thorium
ThO2
EWZr-1
Brown
Zirconium
ZrO2
.25
EWG
Grey
Not Specified**
* Colour may be applied in the form of bands, dots, etc, at any point on the surface of the
electrode.
** Manufacturers must identify the type and nominal content of the rare earth oxide additions.
TUNGSTEN TIP
PREPARATION
DCSP (EN) or DCRP (EP)
Flat: 1/4 to
1/2 x dia
2-3 dia
Taper Length
TUNGSTEN EXTENSION
Standard Parts
General
Purpose
3 x dia.
ACHF
General Purpose
Max.
ball
1 x dia
Ball tip by arcing on clean metal at
low current DCRP (EP) then slowly
increase current to form the desired
ball diameter. Return setting to AC.
TUNGSTEN GRINDING
Shape by grinding longitudinally (never radially). Remove the sharp point
to leave a truncated point with a flat spot. Diameter of flat spot determines
amperage capacity. (See below.)
The included angle determines weld bead shape and size. Generally, as the
included angle increases, penetration increases and bead width decreases.
Use a medium (60 grit or finer) aluminium oxide wheel.
14
TIG WIRES
The selection of the TIG wire to be used in the TIG process is a decision
that will depend on
4) Joint design
6) Cost
15
SHIELDING GAS
Like other welding processes the job of the shielding gas is to protect the
weld pool from contamination from air, which can cause porosity and defects
in the weld. The shielding gas is a pathway for the welding arc and will help
in the starting and running of the welding arc.
In New Zealand the most common gas being used for TIG welding is Argon
gas.
Overseas Helium is also being used and in days gone by in some countries
the weld process was called Heliarc welding.
Each of these two gases has advantages.
Argon
1)
2)
3)
4)
Helium
1)
2)
3)
Faster travel
Better penetration
Higher arc voltages
Because of the cost of Helium we are now seeing mixtures of Argon and
Helium. This is to gain the best part of each gas. Please see your local gas
16
Thickness
Range
Weld
Type
Shield
Gas Type
Thin
Manual
Pure Argon
Thick
Manual
75 Ar - 25 He
Manual
Pure Argon
Magnesium
General
Purpose
Alloys
Thin
Mechanised
50 Ar - 50 He
Thick
Mechanised
Pure Helium
Thin
Manual
Pure Argon
Thick
Manual
75 Ar - 25 He
General
Purpose
Manual
75 Ar - 25 He
Thin
Mechanised
25 Ar - 75 He
Thick
Mechanised
Pure Helium
Thin
Manual
Pure Argon
Thick
Manual
75 Ar - 25 He
General
Purpose
Manual
Pure Argon
Thin
Mechanised
Pure Argon
Thick
Mechanised
75 Ar 25 He
Aluminium
Alloys and
Copper
Alloys
Cu-Ni Alloys
Nickel
Alloys
Low Carbon
Alloys and
Low Alloy
Steels
Characteristics
17
Joint
Type
Butt
Fillet
Butt
Fillet
Butt
Fillet
Butt
Fillet
Tungsten
size
Filler
Rod
Size
Cup
Size
Type
CFH
(L/Min)
PSI
1.6 mm
1.6 mm
4, 5, 6
Argon
15 (7)
20
2.4 mm
2.4 mm
3.2 mm
6, 7
Argon
17 (8)
20
3.2 mm
3.2 mm
7, 8
Argon/
Helium
21 (10)
20
4.8 mm
3.2 mm
8, 10
Argon/
Helium
25 (12)
20
Welding
Amperes
Travel
Speed
60-80
70-90
125-145
140-160
190-220
210-240
260-300
280-320
307 mm
256 mm
307 mm
256 mm
258 mm
230 mm
256 mm
205 mm
WELDING ALUMINIUM
The use of TIG welding for aluminium has many advantages for both manual and automatic
processes. Filler metal can be either wire or rod and should be compatible with the base alloy.
Filler metal must be dry, free of oxides, grease, or other foreign matter. If filler metal becomes
damp, heat for 2 hours at 120oC before using. Although ACHF is recommended, DCRP has
been successful up to 2.4mm, DCSP with helium shield gas is successful in mechanised
applications.
MAGNESIUM (ACHF)
Metal
Gauge
1.6 mm
3.2 mm
6.4 mm
12.8 mm
Joint
Type
Butt
Fillet
Butt
Fillet
Butt
Butt(2)
Butt(2)
Tungsten
size
Filler
Rod
Size
Cup
Size
Type
CFH
(L/Min)
PSI
1.6 mm
2.4 mm
3.2 mm
5, 6
Argon
13 (5)
15
2.4 mm
3.2 mm
4.0 mm
7, 8
Argon
19 (9)
15
4.8mm
4.0 mm
Argon
25 (12)
15
6.4 mm
4.8 mm
10
Argon
35 (17)
15
Welding
Amperes
60
60
115
115
100-130
110-135
260
Travel
Speed
512 mm
435 mm
563 mm
512 mm
256 mm
WELDING MAGNESIUM
Magnesium alloys are in three groups, they are (1) aluminium-zinc-magnesium, (2) aluminiummagnesium, and (3) maganese-magnesium. Since magnesium absorbs a number of harmful
ingredients and oxidize rapidly when subjected to welding heat, TIG welding in an inert
gas atmosphere is distinctly advantageous, the welding of magnesium is similar, in many
respects, to the welding of aluminium. Magnesium was one of the first metals to be welded
commercially by TIG. Magnesium requires a positive pressure of argon as a backup on the
root side of the weld.
18
Joint
Type
Butt
Fillet
Butt
Fillet
Butt
Fillet
Butt
Fillet
Tungsten
size
Filler
Rod
Size
Cup
Size
Type
CFH
(L/Min)
PSI
1.6 mm
1.6 mm
4, 5, 6
Argon
11 (5.5)
20
1.6 mm
2.4 mm
4, 5, 6
Argon
11 (5.5)
20
2.4 mm
2.4 mm
3.2 mm
3.2 mm
5, 6, 7
Argon
13 (6)
20
3.2 mm
4.8 mm
8, 10
Argon
13 (6)
20
Welding
Amperes
Travel
Speed
80-100
90-100
120-140
130-150
200-250
307mm
256 mm
307 mm
256 mm
307 mm
225-275
256 mm
275-350
300-375
256 mm
205 mm
Joint
Type
Butt
Fillet
Butt
Fillet
Butt
Fillet
Butt
Fillet(2)
Tungsten
size
Filler
Rod
Size
Cup
Size
Type
CFH
(L/Min)
PSI
1.6 mm
1.6 mm
4, 5, 6
Argon
15 (7)
20
1.6 mm
2.4 mm
2.4 mm
4, 5, 6
Argon
15 (7)
20
2.4 mm
3.2 mm
7, 8
Argon
16 (6.5)
20
3.2 mm
4.0 mm
8, 10
Argon
18 (8.5)
20
Welding
Amperes
Travel
Speed
95-135
95-135
145-205
145-205
210-260
210-260
240-300
240-300
384 mm
384 mm
282 mm
282 mm
256 mm
256 mm
256 mm
256 mm
Electrode
Diameter
(mm)
Cup
Size
0.50
3, 4 or 5
AC
Zirconiated
DCSP
Thoriated
5 - 20
5 - 20
Argon Flow
- Ferrous Metals
Standard
Body
Gas Lens
Body
Argon Flow
- Aluminium
Standard
Body
Gas Lens
Body
CFH (L/min)
CFH (L/min)
CFH (L/min)
CFH (L/min)
5-8 (3-4)
5-8 (3-4)
5-8 (3-4)
5-8 (3-4)
1.00
4 or 5
15 - 80
20 - 80
5-10 (3-5)
5-8 (3-4)
5-12 (3-6)
5-10 (3-5)
1.60
4, 5 or 6
70 - 150
50 - 150
7-12 (4-6)
5-10 (3-5)
8-15 (4-7)
7-12 (4-6)
2.40
6, 7 or 8
140 - 235
135 - 235
10-15 (5-7)
8-10 (4-5)
10-20 (5-10)
10-15 (5-7)
3.20
7, 8 or 10
220 - 325
240 - 350
10-18 (5-9)
8-12 (4-6)
12-25 (6-12)
10-20 (5-10)
4.00
8 or 10
300 - 425
350 - 500
15-27 (7-12)
10-15 (5-7)
15-30 (7-14)
12-25 (6-12)
4.80
8 or 10
400 - 525
475 - 800
20-35(10-17)
12-25 (6-12)
25-40 (12-19)
15-30 (7-14)
6.40
10
500 - 700
700 - 1100
25-50(12-24)
20-35 (10-17)
30-55 (14-26)
25-45 (12-21)
Tungsten Electrode
Welding Rod
60o - 75o
Shield Gas
Nozzle
15o - 30o
Direction of Travel
The suggested electrode and welding rod angles for welding a bead on
plate. The same angles are used when making a butt weld. The torch is
held 60o -75o from the metal surface. This is the same as holding the torch
15o - 30o from the vertical.
Take special note that the rod is in the shielding gas during the welding
process.
20
PULSED TIG
Pulsed TIG has the advantages of
1) better penetration with less heat
2) less distortion
3) better control when welding out of position
4) Easy to use on thin materials
The down side is - more set-up cost and more operator training.
Pulsed TIG consists of
Peak Current - This is set up higher than for non-pulsed TIG.
Background Current - This is set lower than peak current and is the bottom
current the pulse will drop to, but must be enough to keep the arc alive.
Pulses Per Second - This is the number of times per second that weld
current reaches peak current.
% on Time - This is the pulse peak duration as a percentage of the total
time, which controls how long the peak current is on for before dropping to
the background current.
Down Slope - This is the way and the time taken for the welding current
to wind down at the end of the TIG weld. Down slope will help prevent the
uneven cooling of the final weld pool and will help stop pinholes forming at
the completion of a TIG weld.
Post Flow - Post flow is the time taken for the shielding gas to stay on after
the welding current has stopped. This time will
1) protect the end of the weld
2) protect the cooling down of the tungsten (the oxidation of the
tungsten).
Pre-Flow - Preflow is used at the start of the welding process to help protect
the start of the weld from contamination and to make sure the shielding gas
is flowing before the welding current starts up.
21
PERSONAL PROTECTION
Skull Cap
Helmet
Mask
Jacket
Welding
helmet lens
Gloves
22
2) Heat
3) Ultra Violet Light - TIG produces one of the highest ratio of ultra
violet light per amperage of any welding process.
4) Fumes - coming from the heating of the base material and the
burning of any contaminates that might be present.
Electrode A has the ball end. This pure tungsten was used with
alternating current on aluminium. Notice the end is uniform in shape and
possesses a shiny bright appearance.
Electrode B is a 2% thoriated tungsten ground to a taper and was used
with direct current straight polarity.
Electrode C is a 2% thoriated tungsten which was used with alternating
current on aluminium. Note that this electrode has several small ball shaped
projections rather than a round complete ball end like the pure tungsten.
Electrode D is a pure tungsten used with alternating current on aluminium.
This electrode was subjected to a current above the rated capacity. Notice the
ball started to droop to one side. It becomes very molten during operation
and continuing to operate would have caused the molten end to drop into the
weld puddle.
Electrode E is a pure tungsten that was tapered to a point and used on
direct current straight polarity. Notice the ball tip characteristic of the pure
tungsten. Pointing of pure tungsten is not recommended as the extreme
point will always melt when the arc is established. The electrode in this
illustration melted back, however, often times the point may melt and drop
into the weld puddle.
Electrode F was severely contaminated by touching the filler rod to the
tungsten. In this case the contaminated area must be broken off and the
electrode reshaped as desired.
Electrode G did not have sufficient gas post-flow. Notice the black surface
which is oxidized because the atmosphere contacted the electrode before it
cooled sufficiently. If this electrode were used the oxidized surface will flake
off and drop into the weld puddle. Post-flow time should be increased so the
appearance is like electrode A after welding.
23
CAUSE:
PROBLEM:
CAUSE:
PROBLEM:
CAUSE:
PROBLEM:
CAUSE:
PROBLEM:
CAUSE:
PROBLEM:
CAUSE:
PROBLEM:
CAUSE:
PROBLEM:
CAUSE:
Excessive build up
Poor penetration
Poor fusion at edges
Undercut
Welding current too high
Insufficient weld deposit and/or wrong placement of
Uneven penetration
filler rod
Poor penetration
Poor fusion
Proper build-up
Good appearance
good penetration
Bead edges fused in
No undercut
Correct technique and
Legs of fillet weld equal current setting
to metal thickness
Slightly convex bead face
24
Cause
Solution
Excessive
Electrode
Consumption
Erratic
Arc
Inclusion of
Tungsten or
Oxides in
Weld
Porosity in
Weld Deposit
Cracking in
Welds
1. Hot cracking in heavy section or with metals 1. Preheat, increase weld bead cross-section size,
which are hot shorts
change weld bead contour. Use metal with fewer
alloy impurities
2. Crater cracks due to improperly breaking
2. Reverse direction and weld back into previous weld
the arc or terminating the weld at the joint
at edge. Use Amptrak or foot control to manually
edge
down slope current
3. Post weld cold cracking, due to excessive
3. Preheat prior to welding, use pure or nonjoint restraint, rapid cooling, or hydrogen
contaminated gas. Increase the bead size. Prevent
embrittlement
craters or notches. Change the weld joint design
4. Centreline cracks in single pass welds
4. Increase bead size. Decrease root opening, use
preheat, prevent craters
5. Underbead cracking from brittle
5. Eliminate sources of hydrogen, joint restraint, and
microstructure
use preheat
25
Inadequate
Shielding
Arc
Blow
Cause
Solution
3. Wind or draughts
4. Excessive electrode stickout
5. Excessive turbulence in gas stream
1. Induced magnetic field from DC weld
current
2. Arc is unstable due to magnetic influences
26