Atomic Hydrogen Welding (AHW)

Shows the AEI welding power source

My job often involves working on interesting and unusual welding related projects and can take me to many a farflung corner of the world. One such welding project involved a welding process you may have never even heard of,
and I will confess, up to a few years ago I was only aware of it in books. The process is called Atomic Hydrogen.
A client of mine for many years, part of the BDC Group, is involved with welding and repairing lifting chains and
continues to use this welding process, even today, because it offers a perfect solution for his application. Although, I
am aware that they are on their last machine, after robbing parts from all their other machines for some time now.
This is not just a nostalgic, historical look about a welding process that has all but passed us by, but more to show
you a process that was common place in the 1930s, and even today offers the best solution to a welding problem,
in this case, welding of lifting chains.
Shows the torch and the position of the two tungstens
It is true I wanted to provide some information, for those of you
whom are interested, and shoot some video footage, as I am acutely
aware that when their welder retires, this may be the end for this
process, at least for me, and it is most unlikely I shall ever come
across the use of Atomic Hydrogen welding in a commercial
environment ever again.
The process was invented by Dr Irving Langmuir in 1926 and was
used extensively before WW2, particularly in Germany.
AHW is an arc welding process that uses an arc between two tungsten electrodes in a shielding gas atmosphere of
hydrogen. Filler may or may not be used. A jet of hydrogen is disassociated as it passes through an electric arc. H2
> H + H = 422kJ. The temperature of the arc is in excess of 3700 C.
The arc is maintained entirely independently of the work. The work is part of the electrical circuit only to the extent
that a portion of the arc comes into contact with the work, at which time, a voltage exists between the work and the
electrodes. The hydrogen can be thought of as simply a transport mechanism to extract energy from the arc plasma
and transferring it to the work. It produces a flame as heat is liberated by the chemical reaction. Iron can be melted
without contamination with carbon, oxygen or nitrogen. Because of the powerful reducing action of the atomic
hydrogen, alloys can be melted without fluxes and without surface oxidation.

Shows macro of completed weld in a 12mm steel bar

A feature of the flame is the speed by which it can deliver heat to the workpiece. When an arc is established in
hydrogen, between two electrodes, the molecular hydrogen dissociates into atomic hydrogen. In the process of
disassociation, large amounts of heat is absorbed from the arc by the hydrogen. This heat is released on
recombination of the hydrogen atoms at the work surface due to hydrogen atoms recombining in their molecule
form.
The operator can control the heat by varying the distance of the arc stream between the two electrodes and the
distance to the workpiece.
The power source is a transformer that has an open circuit voltage (OCV) of up to 300 volts to strike the arc, but
welding current is low, with generally amperages of 10-20 being used, although this particular AEI model offers a
maximum of 50 amps

Atomic hydrogen arc Welding

Definition
Atomic hydrogen welding is a thermo - chemical welding process in which the work pieces are joined by the
heat obtained on passing a stream of hydrogen through an electric arc struck between tow tungsten electrodes. The arc
supplies the energy for a chemical reaction to take place, thereafter heat is obtained for welding. Filler rod may or may not
be used during the process.
Operation of Atomic Hydrogen Welding:

The equipment consists of a welding torch with two tungsten electrodes inclined and adjusted to maintain a stable arc.
Annular nozzles around the tungsten electrodes carry the hydrogen gas supplied from the gas cylinders.
AC power source is suitable compared to DC, because equal amount of heat will be available at both the electrodes. A
transformer with an open circuit voltage of 300 volts is required to strike and maintain the arc.
The work pieces are cleaned to remove dirt, oxides and other impurities to obtain a sound weld. Hydrogen gas supply
and welding current are switched ON.
An arc is suck by bringing the tow tungsten electrodes in contact with each other and instantaneously separated by a
small distance, say 1.5 mm, such that the arc still remains between the two electrodes.
As the jet of hydrogen gas passes through the electric arc, it disassociates into atomic hydrogen by absorbing large
amounts of heat supplied by the electric arc.
H2H+H-422 KJ (Endothermic Reaction)
The heat thus absorbed can be released by recombination of the hydrogen atoms into hydrogen molecule (H2)
Recombination takes place as the atomic hydrogen touches the cold work piece liberating a large amount of heat.
H + H H2 + 422 KJ (Exothermic reaction)

Advantages of Atomic Hydrogen Welding:

Intense flame is obtained which can be concentrated at the joint. Hence, less distortion.

Welding is faster.
Work piece do not form a part of the electric circuit. Hence, problems like striking the arc and maintaining the arc
column are eliminated.

Separate flux / shielding gas is not required. The hydrogen envelop itself prevents oxidation of the metal and the
tungsten electrode. It also reduces the risk of nitrogen pick - up.
Disadvantages of Atomic Hydrogen Welding:

Cost of welding by this process is slightly higher than with the other process.

Welding is limited to flat positions only.

Applications of Atomic Hydrogen Welding:
Atomic hydrogen welding is used in those applications where rapid welding is necessary, as for stainless steels and other
special alloys.