Tungsten Inert Gas welding (TIG) or Gas-tungsten arc welding (GTAW):

Tungsten Inert Gas welding (TIG), which is usually called Gas-tungsten arc
welding (GTAW), is an arc welding process that employs the heat generated by
an electric arc between a non-consumable tungsten electrode and the work
piece.

A filler rod may be fed to the arc zone. A shielding of inert gas (argon or helium)
is used to avoid atmospheric contamination of the molten weld pool.

A TIG unit consists of:

(i) Power supply; either D.C or A.C. to produce arc.

(ii) A gas supply unit, with pressure gauge and flow meter.

(iii) A TIG Welding torch.

(iv) A non consumable Tungsten electrode.

(v) A filler rod.

Power source for Tungsten Inert Gas Welding (TIG):
All three types of current supplies (i.e. A.C., DCSP, and DCRP) can be used
with TIG welding depending upon the metal to be welded.

The choice of which consider the following:

(i) DCRP (Direct Current Reverse Polarity):
For thin sheets of aluminum and magnesium alloys:

(ii) DCSP (Direct Current Straight Polarity):

For high melting point alloys such as alloy steels, stainless steels, heat-
resisting alloys, copper alloys, nickel alloys and titanium.

(iii) AC (Alternating Current):

For normal sheets of aluminum and magnesium.

Inert Gas Supply:

Shielding gases are used to protect the welding pool from atmospheric gases
like nitrogen, oxygen otherwise these gases can damage the welding surface by
creating porosity, blowhole, etc.
Choosing of Shielding gases depends on the types of welding as well as the
atmospheric condition along with the type of metal used for the operation and
many more.

However, generally, we use Argon as a shielding gas in TIG Welding. Sometimes

Argon-helium mixtures are also used in this type of welding.

Argon Gas Cylinders

TIG Welding Torch:

TIG involves the use of specially made electrode holder known as TIG Welding
Torch. A tuhgsten electrode is inserted in the torch. A passage around the
electrode is provided for the flow of inert gas to the weld zone. If the current is
less than 200 amperes, air cooled torch is used; and for current more than 200
amperes, water cooled torch is used.

TUNGSTEN ELECTRODE:

In TIG Welding we use a non-consumable electrode made of Tungsten or

Tungsten Alloy.

Due to High-temperature resisting capacity (Melting Temp of Tungsten is

3,422 °C ) of tungsten rather than any other metal, that’s why we use the
tungsten electrode.
To produce a good quality weld, tip shape tungsten electrode is chosen
according to the type of power supply and the thickness of the metal to be
weld.

Some generally used tips are shown in Fig. below. A conical shape tip for
DCSP, A blunt end conical shape tip for DCRP, whereas, a rounded tip is used
for ACHF.

Working Principle of Tungsten Inert Gas Welding:

When we switch on the machine the high-frequency generator provides an

electric spark.

The electric spark is struck between the Workpiece and the Electrode either by
touching electrode by scrap material or by using a high-frequency unit.

We need to do this operation (Touching with the scrap material) at least 2-3
times to warm up the electrode before the actual operation started. Due to this,
we can save the breaking of the electrode tip.

In actual operation, the heat generated by the electric spark which fuses the
metal from the joint area and it produce a molten weld pool. The size of the
pool depends on the size of the electrode and the amount of the current
supplied by the generator.

The arc area is surrounded by an inert or reducing gas shield to protect the
weld pool and the non-consumable electrode.

The process may be operated autogenously, that means without filler material
or filler material may be added by feeding a consumable wire or rod into the
established weld pool.

Tungsten Inert Gas Welding produces very high-quality welds across a wide
range of materials with thicknesses up to about 8 or 10mm.
Advantages of Tungsten Inert Gas Welding (TIG Welding):
1. Tungsten Inert Gas Welding produces high quality welds.
2. The weld is automatically protected by the inert gas during the welding
process.
3. No slag is produced.
4. TIG Welding can be done in any position.
Disadvantages of Tungsten Inert Gas Welding:
1. Tungsten inert gas welding is a slow process.
2. Highly skilled labour is needed.
3. Welder is exposed to huge intensities of light.
4. TIG welding is more expensive when compared to MIG welding.
Applications of Tungsten Inert Gas Welding:
TIG Welding is used for welding a variety of metals. Some of them are:

1. Stainless steel
2. Alloy steel
3. Aluminium
4. Titanium
5. copper
6. magnesium
7. nickel alloys