IWE kurs, IZ Tuzla, 2015

1.7 TIG postupak zavarivanja

Ismar Hajro, v.prof.dr.

Mašinski fakultet Sarajevo
M: +387 61 227135
E: hajro@mef.unsa.ba

1.7 TIG postupak zavarivanja | Mikro i makro shema

Opšte o postupku Prema AWS-u
IWE Kurs

 Because of the high quality of welds that can be produced by gas

tungsten arc welding, the process has become an indispensable tool
for many manufacturers, including those in the aerospace, nuclear,
marine, petrochemical and semiconductor industries.

 The possibility of using helium to shield a welding arc and weld pool
was first investigated in the 1920s.
 However, there was no incentive for further development or use of
this process until the beginning of World War II, when a great need
emerged in the aircraft industry to replace riveting as the method for
joining reactive materials, such as aluminum and magnesium.

Titan Welding &

LincolnElectric
2 (P51 Mustang)

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 1.7 TIG postupak zavarivanja | Mikro i makro shema
Prednosti i nedostaci Prema AWS-u
IWE Kurs

Prednosti TIG Nedostaci TIG

GTAW GTAW
Advantages Disadvantages

 Clean, high-quality welds  Lower deposition rates

 Welds a wide range of metals
 No spatter or slag, sparks, or
smoke
 Allows for welding in all
positions
 Requires high level of operator
skill
 Higher level of UV rays
 Requires good eye and hand
coordination to achieve quality
weld

Skraćenice / Nazivi / Oznake postupka

 TIG, WIG, GTAW, 141
 argonsko zavarivanje
 DC, AC, DCEN, DCEP... (tipovi struje za zavarivanje)
3

1.7 TIG postupak zavarivanja | Mikro i makro shema

Ograničenja (Nedostaci...?) Prema AWS-u
IWE Kurs

1. Deposition rates are generally lower than the rates possible with
consumable electrode arc welding processes;
2. Slightly more dexterity and coordination is required of the welder
using GTAW than with gas metal arc welding (GMAW) or shielded
metal arc welding (SMAW) manual welding;
3. There is a low tolerance for contaminants on filler or base metals;
4. For welding thicknesses under 10 mim (3/8 inch [in.]), the GTAW
process produces weld quality comparable to or better than the
consumable arc welding processes, but it is more expensive;
5. Magnetic fields leading to arc blow or arc deflection, as with other
arc processes, can make gas tungsten arc welding difficult to control;
6. If welding takes place in windy or drafty environments, it can be
difficult to shield the weld zone properly.

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 1.7 TIG postupak zavarivanja | Mikro i makro shema
Područja primjene Prema AWS-u
IWE Kurs

Procesna industrija

Postrojenja za proizvodnju polu-provodnika

(elektro-industrija)
Millions of orbital gas tungsten arc fusion welds
have been applied in semiconductor fabrication
plants worldwide to join small-diameter tubing,
fittings and other components used in gas
distribution systems, where weld quality is
especially critical...

1.7 TIG postupak zavarivanja | Mikro i makro shema

Područja primjene Prema AWS-u
IWE Kurs

Termoenergetika | Zavarivanje debelostjenih cjevovoda orbitalnim TIG postupkom u uskom žlijebu

3
 1.7 TIG postupak zavarivanja | Mikro i makro shema
Područja primjene Prema AWS-u
IWE Kurs

Avioindustrija | Autogeno (bez dodatnog materijala) TIG zavarivanje komponenti (odlivaka) od nerđajućeg čelika

1.7 TIG postupak zavarivanja | Mikro i makro shema

Područja primjene Prema AWS-u
IWE Kurs

Brodogradnja | Autogeno (bez dodatnog materijala) TIG zavarivanje komponenti od Cu-legura

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 1.7 TIG postupak zavarivanja | Mikro i makro shema
Područja primjene Prema AWS-u
IWE Kurs

Skladištenje nuklearnog otpada | TIG topla žica za zavarivanje buradi od nerđajućeg čelika (u fazi ispitivanja)

1.7 TIG postupak zavarivanja | Mikro i makro shema

Područja primjene Prema AWS-u
IWE Kurs

Prefabrikacija cjevovoda| Orbitalni TIG

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 1.7 TIG postupak zavarivanja | Mikro i makro shema
Princip rada
IWE Kurs

Mikro shema |
Linde Gas

Prema AWS

11

1.7 TIG postupak zavarivanja | Mikro i makro shema

Mikro shema
IWE Kurs

Netopiva elektroda
Smjer zavarivanja
Dodatni materijal, DM
Vrh pištolja (gasne
mlaznice) Izvor toplote
električniluk
Električni luk

Zona topljenja ili Zaštitni (inertni)

Metal šava gas Zaštitni
inertni gas

Metalna kupka Osnovni materijal, OM

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 1.7 TIG postupak zavarivanja | Mikro i makro shema
Makro shema
IWE Kurs

Makro shema TIG postupka |

13 Miller

1.7 TIG postupak zavarivanja | Konstrukcija pištolja (gorionika)

Konstrukcija pištolja (gorionika) | Gasom hlađen
IWE Kurs

Pištolj za TIG zavarivanje |

Miller GTAW Handbook

Gasna Netopiva Navrtka - stezač

mlaznica (volframska) elektrode
elektroda Držač elektrode

Gasna
predmlaznica Tijelo pištolja

Zaštitnim gasom i okolnim zrakom

hlađeni TIG pištolj

Tipovi i klasifikacija TIG pištolja |

EWE Course Lectures 2002

Tipovi Klasifikacija

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 1.7 TIG postupak zavarivanja | Konstrukcija pištolja (gorionika)
Konstrukcija pištolja (gorionika) | Vodom hlađen
IWE Kurs

Pištolj za TIG zavarivanje |

Miller GTAW Handbook

Dovodno i odvodno crijevo

vode za hlađenje

Vodom hlađeni TIG pištolj

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1.7 TIG postupak zavarivanja | Konstrukcija pištolja (gorionika)

Konstrukcija pištolja (gorionika) | Vodom hlađen
IWE Kurs

Prema AWS

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 1.7 TIG postupak zavarivanja | Konstrukcija pištolja (gorionika)
Dodatna oprema (daljinsko upravljanje)
IWE Kurs

Oprema za daljinsku kontrolu za

TIG zavarivanje |
Miller GTAW Handbook

Nožna kontrola za jačinu struje zavarivanja (pedala)

17 Ručna kontrola za jačinu struje zavarivanja (na pištolju)

1.7 TIG postupak zavarivanja | Konstrukcija pištolja (gorionika)

Izbor gasne šobe (mlaznice)
IWE Kurs

Prema AWS
u zavisnosti od tipa i jačine struje...

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 1.7 TIG postupak zavarivanja | Netopiva volframska elektroda
Opšte karakteristike
IWE Kurs

 In gas tungsten arc welding, the function of a tungsten electrode is to

serve as one of the electrical terminals of the arc, which supplies the
heat required for welding.
 Its melting point is 3410°C (6170°F). Tungsten becomes thermionic
when it approaches a temperature this high; therefore it is a ready
source of electrons.
 The tungsten electrode reaches the melting temperature by
resistance heating.
 Without the significant cooling effect of electrons emanating from the
electrode tip, the resistance heating would cause the tip to melt.
Because of this cooling effect, the electrode tip is much cooler than
the immediate area adjacent to the tip.

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1.7 TIG postupak zavarivanja | Netopiva volframska elektroda

Opšte karakteristike
IWE Kurs

 Current levels in excess of those recommended for a given electrode

size and tip configuration will cause the tungsten to erode or melt.
Tungsten particles may fall into the weld pool and be considered
defects in the weld joint.
 Current that is too low for a specific electrode diameter can cause arc
instability.

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 1.7 TIG postupak zavarivanja | Netopiva elektroda | Klasifikacija | EN 26848
Tipovi i klasifikacija volframskih – netopivih elektroda |
IWE Kurs

EWE Course Lectures 2005

21

1.7 TIG postupak zavarivanja | Netopiva elektroda | Klasifikacija | AWS

Klasifikacija elektroda za TIG
IWE Kurs

zavarivanje |
Miller GTAW Handbook

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 1.7 TIG postupak zavarivanja | Netopiva elektroda | Priprema
Način pripreme i stabilnost električnog luka
IWE Kurs

Preporuke za pripremu vrha Pravilna priprema

elektrode vrha elektrode

Način pripreme netopive elektrode za TIG

zavarivanje |
Miller GTAW Handbook

Pogrešna priprema
23 vrha elektrode Prečnik kugle ne smije preći 1,5 prečnika elektrode

1.7 TIG postupak zavarivanja | Netopiva elektroda | Priprema

Uticaj načina pripreme vrha volframske elektrode na el.luk i penetraciju
IWE Kurs

Prema AWS
TIG, Argon, 150A, DCEN

 various geometries of the electrode tip affect the weld bead shape and size. In
general, as the included angle increases, the weld penetration increases and the
width of the weld bead decreases.
 although small-diameter electrodes can be used with a square end preparation
24 for DCEN welding, conical tips provide improved welding performance...

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 1.7 TIG postupak zavarivanja | Netopiva elektroda | Struja zavarivanja
Prečnik elektrode, gasne mlaznice i struja zavarivanja
IWE Kurs

Prečnik elektrode i jačina struje zavarivanja |

Miller GTAW Handbook

25

1.7 TIG postupak zavarivanja | Netopiva elektroda

Netopiva elektroda | Područja primjene
IWE Kurs

Al i legure

Cu i legure

Mg i legure

Ni i legure

Fe i legure
čelici

Ti, Zr, Ha i
legure
Teško-topivi
metali, Nb,
Mo, Ta, W,
Re...

Tip elektorde i podrućje primjene |

26 Miller GTAW Handbook

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 1.7 TIG postupak zavarivanja | Netopiva elektroda
Netopiva elektroda | Trošenje
IWE Kurs

Tipovi trošenja netopive elektrode |

27 Miller GTAW Handbook

1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja

Elektroda i tip struje (DC ili AC)
IWE Kurs

Tipovi struje za TIG zavarivanje |

EWE Course Lectures 2005

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 1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja
Statička karakteristika Izvora struje | Zavisnost Napon – Struja
IWE Kurs
Prema AWS

 A drooping volt-ampere characteristic is typical of magnetically

controlled power source models, including the moving coil, moving
shunt, moving core reactor, saturable reactor, or magnetic amplifier
models and also rotating power source designs.
 A true constant current output can be achieved with electronically
controlled power sources.
 The drooping characteristic is an advantage for manual welding when a
remote foot pedal current control is not available at the site of
welding.
 With a drooping characteristic, the welder can vary the current level
slightly by changing the arc length.

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1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja

Napon električnog luka zavisi od...
IWE Kurs

Prema AWS

Arc voltage, which is generally proportional to arc length, is a dependent

variable that is affected in decreasing amounts by the following:
1. The distance between the tungsten electrode and the workpiece,
2. Welding current,
3. Type of shielding gas,
4. The shape of the tungsten electrode tip, and
5. Ambient air pressure.

Statička karakteristika
30 električnog luka

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 1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja
Napon električnog luka zavisi od...
IWE Kurs
Prema AWS

Tipa zaštitnog gasa

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1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja

Pulsirajuća DC struja za TIG zavarivanje
IWE Kurs

Prema AWS

There are several advantages of pulsed current.

 For a given average current level, greater penetration (useful for metals
sensitive to heat input) can be obtained with pulsed current than with
continuous current.
 Pulsed current also minimizes distortion.
 Because there is insufficient time for significant heat flow during the
short duration of a pulse, metals of dissimilar thicknesses usually
respond equally, and equal penetration can be achieved.
 For a similar reason, very thin metals welding variables can be used on
a joint in all positions, such as those required by a circumferential
weld in a horizontal pipe.
 Pulsed dc is also used for bridging gaps in open root joints.
 Although most often used for mechanized and automatic GTAW,
pulsed current offers advantages for manual welding.
 Inexperienced welders find that they can improve their proficiency by
counting the pulses (from 1/2 to 2 pulses per second) and using them
to time the movement of the torch and the cold wire.
 Experienced welders are able to weld thinner materials, dissimilar
alloys and thicknesses with less difficulty.
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 1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja
Pulsirajuća DC struja za TIG zavarivanje
IWE Kurs
Prema AWS

Visokofrekventna pulsirajuća struja

Varijable koje određuju karakteristike pulsirajuće struje

(podešavaju se na Izvoru struje)

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1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja

Visokofrekentna (HF) Pulsirajuća DC struja za TIG zavarivanje
IWE Kurs

Prema AWS

 Switched DC involves switching from a low current level to a high level

at a rapid, fixed frequency.
 The peak current-on time is varied to change the average current level.
A fixed frequency of approximately 20 kilohertz (kHz) can be obtained
with switching.
 The main reason for switching is to produce a constricted or “stiff”
welding arc.
 A constricted arc provides a more concentrated heat source.
 Arc pressure is a measure of arc stiffness (Slika na prethodnom slajdu)
 When the switching frequency nears 10 kHz, arc pressure increases to
nearly four times that of a steady dc arc.
 As arc pressure increases, lateral displacement of the arc, such as that
produced by magnetic fields (arc blow) and shielding gas movement
caused by wind, is reduced.
 High-frequency switched DC is useful in precision mechanized and
automatic welding applications that require an arc with exceptional
directional properties and stability.

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 1.7 TIG postupak zavarivanja | Tipovi struje zavarivanja
Varijabilna naizmjenična struja „kvadratnog-profila“
IWE Kurs
Prema AWS
za TIG zavarivanje
Variable Square-Wave AC
 Square-wave AC power sources adjust the
current level during the electrode positive
and electrode negative cycles at the
standard 60 Hz frequency.
 Functions provided by the more
sophisticated power sources adjust the
time of each polarity half cycle as well as
the current level during that half cycle.
 These variable wave forms will adjust the
welding current to suit a particular
application.
 Power sources with variable polarity
capabilities developed during the 1990s
have provided the means to adjust the
DCEN interval up to 90-95%. This greatly
increases weld penetration while reducing
the heating of the tungsten electrode, thus
allowing the pointed tungsten electrode
35 geometry to be maintained.

1.7 TIG postupak zavarivanja | Zaštitni gasovi

Zaštitni gasovi | Karakteritike, skladištenje i upotreba
IWE Kurs

Rukovanje bocama za zaštitni gas |

Miller GTAW Handbook

Pomjeranje boce rotiranjem na

jednoj ivici

Elementi zaštite boce

36 Osiguranje boca

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 1.7 TIG postupak zavarivanja | Zaštitni gasovi
Uticaj na kvalitetu (geometriju metala šava) Zaštitni gasovi za TIG zavarivanje |
IWE Kurs

EWE Course Lectures 2005

Zaštitni gasovi | Područje primjene

37

1.7 TIG postupak zavarivanja | Zaštitni gasovi

Potrošnja (protok) zaštitnog gasa u funkciji debljine materijala
IWE Kurs

Potrošnja zaštitnog gasa pri TIG zavarivanju |

EWE Course Lectures 2005

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 1.7 TIG postupak zavarivanja | Zaštitni gasovi
Preporuke za izbor protoka zaštitnog gasa
IWE Kurs
Prema AWS

 Shielding gas flow requirements are based on gas nozzle size, weld pool
size, and air movement.
 In general, the flow rate increases in proportion to the cross-sectional area
at the nozzle (considering the obstruction caused by the collet).
 The gas nozzle diameter is selected to suit the size of the weld pool and the
reactivity of the metal to be welded.
 The minimum flow rate is determined by the need for a stiff gas stream to
overcome the heating effects of the arc and cross-drafts.
 With the more commonly used torches, typical shielding gas flow rates are 7
to 16 liters per minute (L/min) (15 to 35 cubic feet per hour [cfh]) for argon
and 14 to 24 L/min. (30 to 50 cfh) for helium.
 Excessive flow rates cause turbulence in the gas stream that may aspirate
atmospheric contamination into the weld pool.
 A crosswind or draft moving at five or more miles per hour can disrupt the
shielding gas coverage.
 The stiffest, non-turbulent gas streams (with high-stream velocities) are
obtained by incorporating gas lenses in the nozzle and by using helium as
the shielding gas.
 However, in deference to cost, protective screens that block airflow are
preferred over increasing the shielding gas flow rate.
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1.7 TIG postupak zavarivanja | Zaštitni gasovi

Zaštita korijena | Backup Purging
IWE Kurs

Prema AWS

 Exposure to air at the back side of the weldment can contaminate the weld when
making the root pass.
 To avoid this problem, the air must be purged from this region.
 Argon and helium are satisfactory for use as the backup purge when welding all
materials.
 Nitrogen can be used satisfactorily for purging the back side of welds in
austenitic stainless steel, copper, and copper alloys.

Pri zavarivanju sučeonih

spojeva na limovima

Pri zavarivanju kružnih spojeva

na cijevima

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 1.7 TIG postupak zavarivanja | Zaštitni gasovi
Zaštita kompletnog proizvoda u komorama sa kontroliranim atmosferama
IWE Kurs
Prema AWS

41

1.7 TIG postupak zavarivanja | Zaštitni gasovi

Pristupi i oprema za zaštitu materijala veće osjetljivosti na kontaminaciju
IWE Kurs

Prema AWS

Barijere za zadržavanje
zaštitnog gasa

Nastavci (na gasnu šobu) pri

zavarivanju Titana

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 1.7 TIG postupak zavarivanja | Zaštitni gasovi
Pristupi i oprema za zaštitu materijala veće osjetljivosti na kontaminaciju
IWE Kurs
Prema AWS

Upotreba gasni mrežica-leća (eng. Gas Lens)

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1.7 TIG postupak zavarivanja | Zaštitni gasovi

Dodatni materijali za zavarivanje TIG postupkom | prema AWS
IWE Kurs

Prema AWS

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 1.7 TIG postupak zavarivanja | Zaštitni gasovi
Problemi pri zavarivanju TIG postupkom | Preporuke za izbjegavanje
IWE Kurs
Prema AWS

45

1.7 TIG postupak zavarivanja | Tehnika zavarivanja

Preporuke za izbor parametara zavarivanja Preporuke za izbor parametara
IWE Kurs

zavarivanja zaTIG postupak |

EWE Course Lectures 2005

46

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 1.7 TIG postupak zavarivanja | Tehnika zavarivanja
Preporuke za izbor parametara zavarivanja Preporuke za izbor parametara
IWE Kurs

zavarivanja zaTIG postupak |

EWE Course Lectures 2005

47

1.7 TIG postupak zavarivanja | Tehnika zavarivanja

Upravljanje pištoljom i dodatnim materijalom
IWE Kurs

Tehnika zavarivanja TIG postupkom |

Miller GTAW Handbook

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 1.7 TIG postupak zavarivanja | Primjeri primjene
Primjer zavarivanja u nadglavnoj poziciji Primjeri primjene TIG postupka |
IWE Kurs

Miller GTAW Handbook

49

1.7 TIG postupak zavarivanja | Parametri zavarivanja

Uticaj parametara zavarivanja Uticaj parametara zavarivanja kod TIG postupka |
IWE Kurs

Miller GTAW Handbook

Usporedba različite frekvencije struje zavarivanja (60Hz lijevo, i

180Hz desno). Povećana frekvencija, x3, sužava i čini električni
luk više usmjerenim. Ovo ima za posljedicu veću penetraciju.

Usporedba profila metala šava pri 250A za Squarewave i

Advanced Squarewave na 12mm debelim Al limovima
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 1.7 TIG postupak zavarivanja | Parametri zavarivanja
Preporuke za zavarivanje Al-legura Preporuke za zavarivanje TIG postupkom |
IWE Kurs

Miller GTAW Handbook

AlMgSi

AlMgCr

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1.7 TIG postupak zavarivanja | Parametri zavarivanja

Preporuke za zavarivanje Al-legura Preporuke za zavarivanje TIG postupkom |
IWE Kurs

Miller GTAW Handbook

AlMgSi

AlMgCr

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 1.7 TIG postupak zavarivanja | Modifikacije postupka | Topla žica
Princip i efikasnost Princip zavarivanja TIG-toplom žicom |
IWE Kurs

ASM Welding Handbook v6

Mikro / Makro shema
TIG topla žica

Brzina deponovanja metala šava za

“hladnu” i “toplu” žicu

Primjena TIG tople žice za robotsko

53 zavarivanje | Lincoln Electric

1.7 TIG postupak zavarivanja | Modifikacije postupka | TIP TIG

Princip i efikasnost Princip zavarivanja TIP TIG |
IWE Kurs

EdCraig - Weldreality
 do x5 veća efikasnost u odnosu na konvencionalni TIG postupak.
 vrlo konkurentan MIG zavarivanju pulsirajućom strujom.
 potpuna kontrola dostavljanja dodatnog materijala.
 predgrijavanje dodatnog materijala (elektrootporno) | slično kao kod TIG-tople žice.
 vibracije - oscilacije dodatnog materijala velikom brzinom omogučavaju
karakterističan oblik metala šava.

Zavarivanje cijevi TIP TIG potupkom

Primjena TIP TIG pri radioničkom zavarivanju

cjevovodnih fitinga | Siemens

Gorionici za TIP TIG

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 1.7 TIG postupak zavarivanja | Modifikacije postupka | A-TIG
Princip i efikasnost
IWE Kurs

 nova varijanta TIG postupka koristi “aktivni premaz” (eng. active flux), koji prevazili
probleme povećanja penetracije.
 koncept je predložen od Instituta Paton 2000. god.
 penetracija se povećava 1,5-2,5 puta u odnosu na konvencionalni TIG postupak.

Princip zavarivanja A-TIG |

New Developments in Advanced Welding

Metode nanošenja aktivnog premaza

(četkanjem i sprejom).
Usporedba TIG i A-TIG postupka za različite
struje zavarivanja

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1.7 TIG postupak zavarivanja | Modifikacije postupka | Orbitalni TIG

Orbitalni TIG Orbitalni TIG (GTAW) |
IWE Kurs

Magnatech

Mikro shema

Makro shema

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