TIG Welding
TIG Welding: Exploring The Art
An Effective and Precise Welding Technique For All Perfectionists!
TIG welding, commonly known as Gas Tungsten Arc Welding (GTAW), is a type of welding in which the weld is produced using a non-consumable tungsten electrode. Another name for it is Heli arc welding. Like MIG welding, it requires a shielding gas, usually argon or helium, to protect the weld region from atmospheric contamination.
TIG welding is the first option for many industries and applications because it provides superb weld quality and versatility. However, it should be noted that TIG welding is a much slower process than its alternatives. To get the best results, one must understand the gas requirements and select the appropriate gas or blend.
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How it Works
The electrode used in TIG welding is tungsten, hence its name, ‘tungsten inert gas welding’. Tungsten’s melting point is incredibly high, which is helpful in the unique way the welding process occurs when using TIG welding.
The electrode heats up exponentially during TIG but doesn’t actually melt. This is what we refer to as non-consumable electrodes. This doesn’t refer to the fact that it lasts forever but to the fact that it becomes a part of the weld.
Consumable electrode procedures are those in which the electrode melts and turns into filler metal. Regardless of whether you are a beginner or an experienced welder, you will find that this is used in a significant number of other welding techniques.
TIG welding melts the base metal. The base metal must be joined using the process—an electric arc forms between the tungsten electrode and the base metal, generating heat. You can use the torch’s thumb wheel or a foot pedal to modify the heat levels.
A shielding gas is used during the TIG welding process to protect the molten metal from interacting with oxygen and water vapor in the atmosphere. This gas is typically composed of argon and occasionally helium or other gases. High-pressure containers are used to store this gas safely and securely.
Understanding How Current Flows: AC And DC
AC is utilized for other tough-to-work-with metals, such as aluminum. Between the electrode and the workpiece, the positive and negative voltages in AC alternate between one and the other. Although it cleans the workpiece, it increases the electrode’s heat. What AC does is help regulate these oxides. That is because it is a complex metal to work with due to the nature of aluminum and its release of certain oxides.
Direct current, or DC, is used to power most metals. There is usually one positive wire and one negative wire. Typically, in DC TIG welding, the workpiece is positive, and the electrode is negative. When this happens, Direct Current Electrode Negative (DCEN) indicates that the electrode is negative and the current is DC. The DCEN is the most commonly used method, and it applies most of the heat to the workpiece itself.
The current flows in a full circle during TIG welding. From the machine to the torch, from the torch to the weld, and finally back into the machine. A work lead is fastened to the workpiece to complete the circuit from the workpiece back to the machine. Filler metal is an alternative when utilizing TIG welding.
What Can Gas Tungsten Arc Welding (GTAW) be Used on
Because of its exceptional adaptability and weld quality, TIG welding excels in a wide range of applications. Mild steel, stainless steel, aluminum, copper, and other metals such as magnesium are just a few of the metals that TIG welding is excellent at combining. With suitable filler materials, TIG welding may even combine disparate metals.
Pros vs Cons Overview
Pros:
- Ability to Weld Thin Materials
- Precise Control
- Material Versatility
- Clean Welds
Cons:
- Equipment Cost
- Shielding Gas Required
- Slower Welding Process
- Difficult to Learn
Pros of TIG Welding
If you are looking for an efficient advantage for applications, then TIG welding is your choice because it holds a lot of valuable benefits. Welds produced by TIG welding are aesthetically beautiful, smooth, and free of deformation or spatter. So when you need to weld pipes, aviation components, and decorative metalwork, where aesthetics and accuracy are essential, you use TIG welding.
The most convenient advantage of TIG welding is that it doesn’t produce much spatter or slag, which means that after you’re done, there is a considerably low mess to clean up. Saving time and labor? Yes, please.
TIG welding has a lot more uses too. When it comes to the materials, TIG can be used on a variety of them. Copper, titanium, stainless steel, aluminum, and whatnot. Because TIG welding has remarkable heat control, there is less chance of burn-through or distortion when combining thin materials.
TIG welding is versatile and may be used in various welding situations since it can be done in a flat, horizontal, vertical, and above position. There is no need for frequent electrode replacements while using TIG since the tungsten electrode does not melt and fuse with the weld. The distinct filler rod improves the overall quality of the weld as it makes way for more exact control over the metal deposit and weld puddle. TIG welding enhances the work environment since it emits fewer fumes than other arc welding techniques.
Cons of TIG Welding
Even though TIG welding has many benefits, it has plenty of negatives you should be aware of. Because TIG requires precise control and separate filler rod feeding, it has been slower than many of the other arc welding techniques, such as MIG welding. Unfortunately, this means that you may have to deal with higher welding expenses.
Compared to different methods, TIG welding requires more work and the ability to master it fully than its contemporaries. It’s a more demanding method and requires the operator to control the filler rod as well as the torch. Because of its use of specialized torches, gas regulators, and precise controls, the equipment can be more expensive than other welding setups.
Gas Requirements
TIG welding requires inert gas to shield the molten metal from contamination during the welding process. The most popular gas used in TIG welding is argon (Ar). For various metals, it is the go-to in TIG. Unfortunately, unlike MIG welding, there is no gasless option for TIG.
These also consist of aluminum, stainless steel, and simple steel. Argon helps in producing neat, high-quality welds and gives a good and stable arc. In specific situations, helium is employed alone or in combination with argon. Compared to pure argon, it provides a hotter arc and deeper weld penetration, but it should be noted that the cost of helium is higher than that of argon.
Blends, such as 75% He and 25% Ar, are used with thicker materials to maximize a welder’s available amperage. There is less penetration but a steadier arc when there is less helium in the mixture. Hydrogen can be added to argon in modest amounts (up to 5%) to enhance arc stability, penetration, and surface oxide cleaning. Which is usually used for nickel alloys and austenitic stainless steel.