Overview of GTAW/TIG Welding Process
Overview of GTAW/TIG Welding Process
GTAW
Gas Tungsten Arc Welding
by electric arc with electrode of
tungsten and gas protection, or TIG
Tungsten Inert Gas
Common names:
Argon
TIG
General Introduction:
It is an electric arc welding process in the
how the union of metals is obtained by
warming of the same, result of an arc that
is established between a non-consumable electrode of
tungsten and the piece. The protection zone of the
electrode and the welding is obtained using a gas
inert, generally argon or a mixture of gases
inert gases (Argon and Helium). The filler metal is placed
in the electric arc achieving its fusion, and the
mix of this with the base metal. The liquid pool is
manipulates controlling the correct fusion of the parts;
the process can be used without supplementary material.
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termination. Welding of alloys
Does not generate splashes, except for a bad one. special, non-ferrous and ferrous,
operation. and applicable to non-materials
Requires little or no cleaning after the common.
welding.
Allows welding in any position.
Productivity is relatively low.
The cost of the spare parts and the equipment is
relatively high.
Welding equipment:
Power source, it is a generator that can be either direct current (DC) and/or
alternating current (AC). The control commands specific to the GTAW process are found in a
headboard that can be, as in the photograph, incorporated into the source, or independent of
this.
Gas protection cylinder, which uses inert gases such as Argon and Helium or a
combination of both. At the head of the cylinder is a flow regulator,
flow meter and a manometer that gives us pressure inside the tank.
In the source, the torch is connected via a hose-cable, which leads to it.
the electrical current, the protective gas and, if there is one, the cooling fluid (water).
The circuit is closed through the ground wire, which connects the power source to the piece to be welded.
Optionally, a cooling unit for the torch is used, which helps reduce the
general size of it and to be able to work with high currents in duty cycles
prolonged. This equipment makes the torch hose assembly more manageable for the
welder.
The energy source is similar to that used in SMAW, but due to the characteristics of the process
GTAW must provide greater precision in adjusting the electric current and allow
soldering with low values of this (it can be reached, depending on the source, to work with 5
Ampere).
Below we see a breakdown of a TIG torch:
Ceramic nozzle.
B) Exhaust port.
C) Tungsten door.
Long stopper.
Short cap.
F) Teflon ring.
G) Button.
H) Mango.
The set of pieces is much more delicate than an SMAW clamp, and requires a lot of care.
part of the welder, particularly to avoid falls, stepping on it, or pulling the hose violently, this can
damage the gas inlet and electrical contacts.
The process:
The arc welding process with tungsten electrode differs from the others.
arc welding processes in 2 fundamental aspects:
Polarity
It is defined as the connection of the electrode to one of the
terminals or poles of the machine.
Inverse Polarity
The polarity is reverse when the electrode is located
connected to the positive pole (+) of the machine. In this case
the flow of electric current (electrons) is from
the piece (which is connected to the negative pole) towards the
electrode, that is, enters into the electrode (See next Fig.).
Direct Polarity
The polarity is direct when the electrode is connected to the negative pole (-) of the
machine. In this case, the flow of electric current is from the electrode to the piece that
find connected to the positive pole of the source (See next Fig.).
Alternating Current
The current alternative change
constantly its sign and value with it
passing time in a cyclical manner. It is
represents as indicated in the figure
contiguous, where a cycle is composed
for 2 semicircles, one above the axis
horizontal, called positive semicircle,
and one below the horizontal axis,
negative semicircle call.
An alternating current of 50 cycles,
It means that in 1 second it changes 100.
sometimes its polarity, passing in form
Alternating from positive to negative polarity. In other words, at one moment the current flows
in one direction and in the next instant it does so in the opposite direction, and so 100 times per second.
It is noteworthy that in alternating current it makes no sense to talk about direct or reverse polarity, because
this is constantly changing.
Pulsating Current
The pulsating current is the one
what changes over time,
Increasing and decreasing its
value, and keeping constant
its polarity.
In a pulsating current, the
periods can be modified according to the need, both in frequency (amount of
periods per second), as in amplitude (height of the wave). The incorporation of electronics each
The increasingly complex design of welding equipment allows for the manipulation of the 'waveform' of the
current, significantly enhancing their performance.
The electric arc is characterized by having a high intensity of electric current and low
arc tension, therefore requires a high concentration of electrons to transport
the current. The heat generated in the cathodic zone is mainly due to the shock produced by the
positive ions against the surface of the cathode. The heat generated in the anodic zone, or on the
anode, is caused by the collision of electrons that have acquired acceleration during
its passage through the plasma due to the action of the tension from the arch, and return the energy
kinetic energy acquired in the form of heat upon impact against the surface of the anode.
The arc plasma is a mixture of neutral and ionized atomic gas (excited). The most...
the hot plasma is the central part of the column, where
the movement is more intense. The outer part of the
the arch column is a bit colder.
By changing the gas that forms the plasma, a change is obtained in the heat balance between the cathode.
and the anode.
Connecting the electrode to the (-) terminal of the machine allows for working with higher intensities without...
the electrode tip melts, which does not happen if it is connected to the (+) pole.
Figure A shows a weld made with DCEN where good penetration is observed,
since the heat concentration originates on the surface of the joint. There is no action of
cleaning with this polarity.
Figure B indicates a weld made with DCEP; with this polarity, a good one is obtained.
cleaning action as a result of the flow of argon gas ions towards the surface of the piece,
whose impacts against it occur with enough force, leading to destruction of
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the surface oxide layer. On the other hand, the flow of electrons towards the electrode causes
a heating effect of it, producing a weld with very little penetration.
Figure C shows a weld made with AC (alternating current), where a combination is made.
good cleaning, carried out during the positive semicircle, and an adequate penetration achieved
during the negative semi-cycle.
It allows welding on very thin thicknesses (less than 1 mm), without the risk of
produce the "puncture" or piercing of the joint.
Allows the welding of those materials (austenitic stainless) in which it is necessary
ensure that the thermal contribution does not exceed the established limits.
It allows to considerably minimize the deformation of the joint.
It allows for better control of the welding fusion puddle, from the point of view
operative.
Working with pulsating current, during the high current half-cycle (also called current
Welding) the fusion and deposition of the rod occurs, while during the semi-period of
low current (called base current) produces the cooling of the droplet (deposited metal).
Operating Principles:
By pressing the button that the torch has on its handle, the entire circuit is energized making
jump the arc between the tip or end of the non-consumable electrode and the base metal. The heat
developed by said arc melts the base metal forming a bath of liquid metal. Both the
electrode like molten metal, and the areas
adjacent, are protected from pollution
atmospheric due to a gas envelope.
One must take the precaution of NOT REMOVING the rod anymore.
beyond the gas protection cone, in order to avoid
its oxidation (the oxidized end of the rod causes
porosities in the deposited metal). The advance of the arc
for a right-handed person, it is from right to left, in such a way,
that the deposited cord remains to the right of the welder.
The length of the electric arc is approximately 1½.
sometimes the diameter of the tungsten electrode, however,
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It depends a lot on the welder's hand. In any case, the length of the arc should not
exceed 5mm at most, as a very long arc dissipates more heat over the surface
of the base metal reducing depth and fusion within the metal. On the other hand, the arc becomes
less stable, increases the risk of contamination, both of the filler metal and the bath of
fusion, in addition to causing greater deformation of the welded joint or seam.
On the other hand, the penetration of the welding will also depend on the speed at which it is applied.
the rod, the greater the deposition of material, the greater the heat absorbed from the arc and consequently
lower heating of the base metal, reducing penetration.
The opening of the arc or completion of the welding occurs by slowly reducing the input with
the rod and simultaneously tilting the torch towards the deposited cord, and gently pulling away
the welding electrode until the arc is completely extinguished. Then, allow the
gas protector continue its flow to the melted bath until it turns dark in color,
after which the gas flow is cut off and the torch is removed.
It would be desirable for a TIG torch to, at a minimum, incorporate the following systems, which will allow
the execution of high-performance welds:
It is a wave generator, very short, whose frequency can be between 100 and 300.
KHz (up to 12 MHz) and with peak voltages of the order of 10 to 20 kV (let's remember
100 KHz corresponds to a change of polarity that occurs 200,000 times per second and 20.
20,000 Volts.
The primary purpose of the HF unit is to produce the ionization of the shielding gas (argon or
helio) so that it constitutes an electric bridge (path) between the tip of the electrode and the
piece, thus allowing the ignition of the electric arc, without the need to open the arc to
through a short circuit (touching the part with the end of the tungsten).
If the HF generating unit is not available, the only way to ignite the electric arc is
scraping the electrode (as if it were a match) against the surface of the base metal (anvil). In
In general, this operation is inadvisable from an operational point of view.
Another important function of the HF appears when working with Alternating Current.
When crossing from the positive semicycle to the negative one, it necessarily passes through a point where
the current is zero (0), meaning that the flow of electricity is interrupted, and to restart the
it would be necessary to cause a short circuit (working with alternating current is practically
impossible). Thanks to the HF in the welding circuit, the ionization it causes in the gases
surrounding the arc, allows for the re-ignition of the arc each time the current passes through zero.
In other words, despite the interruption of the electrical current, the arc does not extinguish.
thanks to the presence of the plasma formed by the gases inside the arc.
If the control allows it, the HF can be activated for the start of the arc or for the entire welding cycle.
In summary, we can say that the HF generator unit is used in a TIG process for:
a. Produce the arc ignition without the need to touch the workpiece with the electrode.
b. Allow the arc to reignite when welding with Alternating Current.
c. Provide greater stability to the electric arc.
d. Ensure a better and more efficient cleaning (removal of oxides) in welding
metals such as Aluminum and Magnesium.
It should be noted that, as a consequence of point (a), two fundamental advantages are obtained.
consist of: preventing contamination of the tungsten electrode with the base metal, and on the other hand,
the deterioration of the tip and subsequent wear due to sharpening it at each interruption
the welding operation.
The purpose of the gas PREflow is primarily to inert the space between the nozzle.
(element that surrounds the electrode and through which the flow of gas is directed) and the
welding surface; and as a second objective to allow this gas to ionize under the
high frequency action.
The function of the POS gas flow is to protect from the surrounding air, the bath of
fusion and the electrode, after the extinction of the electric arc. The post-flow must be regulated from
in a way that it maintains the necessary time until the bath has solidified and its color
has acquired the appearance of dark gray.
The post-flow is important, not only to prevent the oxidation of the metal and the electrode, but also
to help prevent the formation of a crater fissure due to the sudden cooling of the last
portion of liquid pool that solidifies.
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This leads to the formation of a concavity in the center of the pool, called Crater. Said
crack, under certain stress conditions, can lead to the joint cracking.
The Anticrater system prevents the formation of the rechupe in the pool during solidification, making
that the welding current, before being interrupted, gradually reduces its intensity until
Achieve a value of approximately 30-40% of the welding amperage used.
Welding Gases
The main function of the shielding gases in the TIG process is to prevent contact with air.
environment with the electrode and the molten metal, at the moment when the welding is carried out.
The gas used also has an influence on the stability, characteristics, and behavior of the
arc, and consequently in the result of the welding.
The gases most commonly used in TIG welding are Argon, Helium, or a combination of them; the
they must have a high purity (usually 99.99%).
For the same arc length and current, Helium requires a higher voltage than Argon to
produce the arc. Due to its excellent thermal conductivity, Helium produces higher temperature
that the Argon in the welded area achieves much greater penetration than with Argon,
resulting more effective in the welding of thick materials, particularly metals such as
copper, aluminum and their alloys.
Argon is better suited for welding metals with lower thermal conductivity and little
thickness, particularly for welding positions other than flat. In the following table, there
They describe the appropriate gases for each type of material to be welded.
The denser the gas, the better its performance will be for arc protection.
Argon is approximately 10 times denser than Helium, and 30% denser than air.
When Argon is used, it forms a dense protective cloud, while the action of Helium is
much lighter and more airy, which disperses quickly. For this reason, it will be necessary
larger amounts of gas in case of using Helium (pure or mixtures that contain mostly
Helium) that if Argon were used.
Currently, Helium has been replaced by Argon, or by mixtures of Argon-Hydrogen or
Argon-Helium. This is because these gases help to improve the generation of the electric arc and
Characteristics of metal transfer during welding promote penetration
increasing produced temperature, the width of the melting zone, the rate of formation of
welding; in addition to reducing the tendency to undermining.
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These gases also provide satisfactory conditions for the welding of the vast majority of the
reactive metals such as aluminum, magnesium, beryllium, columbium, tantalum, titanium, and zirconium.
It is noteworthy that Argon-Hydrogen or Helium-Hydrogen mixtures can only be used for the
welding of a few metals, such as some stainless steels and alloys of
nickel.
The electrode
The electrode used in TIG welding differs from those used in other processes.
electric arc welding, because it does not melt with the heat generated by the electric arc, and for the
so it does not provide material to the welding. However, if an incorrect electrode is selected or is
it applies too high a current, electrode particles can transfer through the arc.
The tungsten electrode or wolfram, used in TIG welding, is very hard and highly
refractory, whose melting point is reached at 3400°C. These electrodes are manufactured in diameters
from 0.5mm to 6mm, and they can be made of pure tungsten or alloyed. Below is presented a
table showing the suggested currents according to the diameter and type of electrode.
General notes:
These values are based on the use of argon as a shielding gas. Other values may be used, depending on the
protection gas (lower values would be applicable using helium as the gas), the type of equipment, and the application.
If no values are given, it implies that its use is not recommended.
Classification of electrodes according to AWS standard
The AWS A5.12 standard classifies tungsten electrodes according to the following designation:
The same standard identifies each type of electrode with a certain color, depending on its
Classification. The following table indicates the types of electrodes and their corresponding color:
The choice of electrode type will largely depend on the type of material desired.
soldering, the type of current to be used and the operational characteristics.
The selection of the electrode diameter must be made taking into account that it,
it should neither be so small that there is a risk of melting its end, nor so large that
lead to arc instability (for a given welding current), as a consequence
from the decrease in electronic emission due to the low heating of the electrode.
Operational aspects:
The tips of the electrodes initially have no shape. Therefore, before being used, they must be shaped.
shape, whether by machining, roughing or casting them. The
forms can be of three types: pointed, half-moon, and ball, and
they will depend on how they are used.
Regarding sharpening, it is advisable to carry out the same longitudinally to the
electrode (see image), designed to facilitate the passage of the
current.
Filler Metal – TIG Rods
In the GTAW process, I can choose not to use filler material, or use the same base metal or piece as filler.
a welding properly prepared (base metal strips for example), or filler rods
standardized substances that are added to the welding bath, the mechanism of which had already been explained
previously.
Depending on the type of base material to be welded, the appropriate rod should be selected that meets
the appropriate physical and chemical properties to perform a good welding. In the majority of
The cases can find rods in the market whose mechanical properties allow for their use.
in a wide spectrum of base materials, which are classified by codes and standards
international, such as AWS, DIN, etc.
The rods are identified according to AWS (American Welding Society) with letters and numbers whose
The meaning is indicated below.
AWS groups the TIG filler rods according to different types identified with a number A [Link]
(corresponding to the identification SFA [Link] according to ASME Sec. II Part C).
The following are some groups, the most used with their respective application:
The following is a table with the most common TIG rods, and a detail of their
applications, classified according to AWS.
AWS [Link] ICA CION APPLICATIONS
120
ERS-1
ER 505 AcerosalomoMoly
Cr / (9.0/1,0%)
ER NiMo-7 /30%Mo )
Ac. Nlquel-Mely (70% You
ER NiCrMo-3 Ac. Nloue l-Cromo-Molv (7020
/ /10%)
NOTE: The consumables listed in the previous table are the most common for each of the AWS groups. For more
information should refer to the ASME Code Section II Part C.
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Bibliographic References:
- Welding Technology, "Prof. Paulo Villani Marques" (National University of Minas Gerais
ASME Code Section II Part C, "Specifications for Welding Rods, Electrodes and Filler"
Metals.
Images in the public domain extracted from the World Wide Web (www).
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