Tungsten Inert Gas (TIG)

The Tungsten inert gas (TIG) welding process fuses

metals by heating them between non- consumable
tungsten electrode and the base metal, while a
continuous envelope of inert gas flows out around the
tungsten electrode.
Application
The TIG process can be used to join most metals.
It welds aluminum and magnesium and their alloys,
alloy steels, carbon steels, stainless steels, copper,
nickel and nickel alloys, titanium, tin, silicon,
aluminum bronzes, and cast iron.
Advantages
Superior quality welds, generally free from spatter,
porosity, or other defects
Precise control of arc and fusion characteristics
Weld almost all metals
Used with or without filler wire Easily automated
Used in all positions
Intricate geometries weldable
 GAS WELDING

Gas welding is a fusion welding process in which

the heat for welding is obtained by the combustion
of oxygen and fuel gas. The fuel gas may be
acetylene, hydrogen, propane or butane.
Application
It is used to join thin metal plates.
It can used to join both ferrous and non-ferrous
metals.
Gas welding mostly used in fabrication of sheet
metal.
Advantages

It can also be used as gas cutting.

Equipment cost is low compare to other welding
processes like TIG,MIG,SPOT etc.
Equipments are more portable than other type of
welding.
 METAL INERT GAS (MIG)

It works on basic principle of heat generation due to

electric arc. This heat is further used to melt consumable
electrode and base plates metal which solidify together
and makes a strong joint. The shielded gases are also
supplied through nozzle which protect the weld zone
from other reactive gases. This gives good surface finish
and a stronger joint.

Application
Stainless steel and nickel alloys
Structural steel.
Aluminum alloy
Some offshore application

Advantages
It provide higher deposition rate.
It is faster comparing to arc welding because it supply
filler material continuously.
It produce clean weld with better quality.
It can be easily automated
WELDING SYMBOLS AND
POSITION
 WELDING DEFECTS
SPATTER
Causes
Welding current too high.
Arc too long.
Incorrect polarity arc blow.
Insufficient gas shielding
Remedies
Reduce welding current.
Reduce arc length.
Check shielding gas type and flow
rate, Clean gas nozzle, Increase torch
to plate angle.
UNDERCUT
Causes
Arc voltage too high.
Arc too long.
Incorrect electrode use or
electrode angle.
Travel speed too high
Remedies
Lower arc voltage, Reduce arc length.
Apply electrode angle of 30 to 45
Reduce travel speed.
Use a smaller diameter electrode.
 WELDING DEFECTS
CRACKS
Causes
Weld cools down too rapidly.
Hydrogen in the weld e.g. because of wet
weld edges, shielding gases.
The base material is prone to hardening
(because of a high C content or other
alloying elements).
Remedies
Remove moisture from welding zone
Use low-hydrogen welding consumables
Apply a higher preheat temperature
DISTORSION
Causes
Plates clamped insufficiently
Unsuitable welding sequence.
Too many and too thin beads, usually
because the electrode is too small.
Remedies
Weld from both sides of the joint. Weld
from the centre out, in opposite directions.
Compensate for shrinkage by fixing the
work pieces with a counter-angle.
 WELDING DEFECTS

OVER PANETRATION POROSITY

Causes
Causes Moisture, rust, grease or paint on the plate
Weld input energy too high
edges.
Incorrect weld preparation i.e excessive root
Insufficient gas shielding.
gap, thin edge preparation
Welding onto small gaps filled with air.
Use electrode unsuited to welding position
Remedies
check welding torch for leaks.
Remedies
Dry or clean plate edges.
Reduce arc power/increase weld speed
Check shielding gas type and flow-rate. Clean
Improve work piece preparation
gas nozzle. Ensure torch to plate angle is not
Use correct electrode position
too small.
 WELDING MEASURING GAUGES

Bridge Cam Weld Gauge HI- LO Gauge Fillet Gauge

WELDING STANDARDS
 WELDING DEFECTS

MISALIGNMENT Incomplete Fusion EXCESSIVE CONVEXITY INCOMPLETE PENETRATION

BURN THROUGH CRATER CRACKS ARC STRIKE EXCESSIVE WELD REINFORCEMENT

UNDERFILL UNDER CUT UNACCEPTABLE WELD PROFILE POROSITY