Categories
Welding Wire & Electrodes
Welding Wire Solid Welding Wire Flux-Cored Welding Wire Metal-Cored Welding Wire Submerged Arc Welding Wire
Welding & Cutting Equipment
Oxy Actylene Welding & Cutting Lighters & Flints Oxy Acetylene Welding & Cutting Torches Oxy Acetylene Welding & Cutting Outfits Quick Connectors Oxy Acetylene Welding & Cutting Torch Attachments Flashback Arrestors Oxy Acetylene Welding & Cutting Torch Handles Burning Bars & Lances Oxy Acetylene Cutting Machine Accessories Oxy Acetylene Cutting Machines
Abrasives
Safety & PPE
Protective Clothing Welding & Fire Resistant Clothing High Visibility Vests & Jackets Aluminized Clothing
Welding Helmets & Lenses Welding Lenses, Filters & Covers Welding Helmets Welding Helmet Replacement Headgear Welding Helmet Accessories
Welding & Cutting Consumables
MIG Welding Consumables MIG Contact Tips MIG Nozzles MIG Diffusers MIG Liners MIG Insulators MIG Drive Rolls Mig Conductor Tubes MIG Consumable Kits
TIG Welding Consumables Tungsten Electrodes TIG Cups TIG Collet Bodies TIG Collets TIG Torch Back Caps TIG Insulators & Gaskets TIG Gas Lenses TIG Consumables Kits TIG Nozzles
Plasma Cutting Consumables Manual Cutting Consumables Manual Plasma Torch Electrodes Manual Plasma Torch Nozzles Manual Plasma Torch Shield Caps Manual Plasma Torch Tips Manual Plasma Torch Retaining Caps Manual Plasma Torch Swirl Rings Manual Plasma Torch Start Cartridges Manual Plasma Torch Consumables Kits Manual Plasma Torch Deflectors Manual Plasma Torch O-Rings Manual Plasma Torch Diffusers Manual Plasma Torch Collets
TIG Welding
TIG Welding, also known as Gas Tungsten Arc Welding (GTAW), is a process that joins metals by heating them with an arc between a tungsten electrode (non-consumable) and the work piece. The process is used with a shielding gas and may also be used with or without the addition of filler metal. The primary variables in TIG Welding are arc voltage (arc length), welding current, travel speed and shielding gas composition. The amount of energy the arc produces is proportional to the current and the voltage. The amount of energy transferred per unit length of weld is inversely proportional to the travel speed. Shielding gases are typically inert to protect the electrode from contamination. The use of helium shielding provides more penetration than argon. The arc, established between the tip of the electrode and the work, generates heat to melt the base metal. Once the arc and weld pool are established, the torch is moved along the joint, and the arc progressively melts the surfaces to be joined. If used, filler wire is usually added to the leading edge of the weld pool to fill the joint. The tungsten electrode can be alloyed with small amounts of active elements to increase emissivity of the electrode; this provides quicker arc starting, greater arc stability, and longer electrode life.
Why Use TIG Welding?
- Can be used to join almost all metals, with superior weld quality, generally free of defects
- Free from spatter that occurs with other arc welding processes
- Can be used with or without filler metal as required for the specific application
- Provides excellent control of root pass weld penetration
- Can be used to produce inexpensive autogenous (fusion) welds with good penetration
- Provides for separate control over the heat input and filler metal additions
Limitations
- Travel speeds and deposition rates are relatively low, increasing weld cost
- A high degree of operator skill is required to produce quality welds
- Process is not easily automated
TIG Welding: How to Improve Results
| Tips and Tricks | Titanium Alloys | High Nickel Alloys | Aluminum Alloys | Copper Alloys | Stainless Steel Alloys (300 Series) |
|---|---|---|---|---|---|
| With cylinder gas supply, use a high integrity gas delivery system in place of standard rubber diaphragm regulator/flowmeter. | X | X | X | X | X |
| Use a gas lens in the TIG torch to support a lamellar gas flow. | X | X | X | X | X |
| Use gas flow rates in the 15-20 cfh range. | X | X | X | X | X |
| Ascertain both raw material and filler metals are clean before welding. | X | X | X | X | X |
| Use a high integrity TIG torch as it utilizes a high integrity gas delivery line which is not permeable to atmospheric gases. The gas line is also separate from the power cable, further enhancing gas purity. | X | X | X | X | X |
| Use a high integrity gas supply line from the flowmeter to the gas solenoid on the welder. Conventional rubber hoses may leak. | X | X | X | X | X |
| If a central gas supply or distribution pipeline is utilized, use a high flow moisture trap and consider use of an oxygen trap. | X | X | X | X | X |
| Use ultra-high purity argon when possible (Grade 5.0 or better), 99.999% purity. | X | X | X | X | X |
| With materials grater than 1/8", consider use of an argon/helium shielding gas blend for improved penetration. | X | X | |||
| Consider adding controlled amounts of hydrogen to the argon-based shielding gas (<10% H2). A CGA 350 regulator will be required when this gas is selected. The CGA 580 used with pure argon will not fit this cylinder. This mixture is not recommended for joining stainless to carbon steel. It is ideal for stainless-to-stainless joining. | X | X | |||
| Use post and pre-flow when possible (1 second for each 10 amps of welding current). | X | X | X | X | X |
| Use a trailing shielding gas if possible. | X | X | X | ||
| Use a high integrity regulator/flowmeter with a stainless steel diaphragm. | X | ||||
| Perform inter-pass cleaning with a 300 series stainless steel brush. This will remove surface oxides for improved results. | X | X | X | ||
| Remove surface oxide in the weld zone using a clean stainless steel brush prior to welding. | X | X | X | ||
| On thicker material, set balance control to maximum penetration when possible. | X | ||||
| Match filler metal to base metal - consult AWS or CWB guidelines. For stainless to steel, use an E309 filler metal. | X | X | X | ||
| For dissimilar alloy joining, consider silver bearing filler metal. Service temperatures must be below the melting point of the alloy selected (typically <900° F). | X | ||||
| If the weld needs to be anodized, use a 5000 series filler metal. | X | ||||
| Use an AC square wave power supply when possible. | X | ||||
| Use a water-cooled TIG torch to prevent the tungsten from melting and improve the current carrying capacity of the torch when welding thicker material. | X | X | X | ||
| Use a pure tungsten electrode and increase the diameter to compensate for additional heat load at the torch. Less than 3/32" thoriated tungsten electrodes are not recommended for welding aluminum. | X | ||||
| Consider using preheat on thick sections. Oxy-acetylene torches work well. Be sure to set a carburizing flame and use a temperature measuring device. | X | X | |||
| Be patient on arc starts. Aluminum and copper have high heat conductivity. Materials will not melt for several seconds. | X | X | |||
| Use a remote foot or hand control to compensate for the high thermal conductivity of aluminum or copper or with thin stainless steel. | X | X | X | ||
| Use Direct Current Straight Polarity (DCSP) electrode negative when possible. Direct Current Reverse Polarity (DCRP) may be used for very thin sections (<1/16"). | X | X | |||
| To improve surface color match and corrosion resistance, use pulsed current settings. | X | X | |||
| Use an alloyed tungsten electrode to increase current carrying capacity. If thoriated tungsten is selected, ensure all grinding dust is captured and removed from the operator's breathing zone. Consult MSDS of the electrode manufacturer. | X | X | |||
| To minimize surface discoloration, maintain close nozzle-to-work distances (maximum 1/2" from work piece). | X | X | |||
| Rapid cool thin sections to maintain corrosion resistance. | X | ||||
| Minimize heat input while maintaining sufficient penetration. | X |
TIG Welding Parameters for Aluminum
| Material Thickness (in) | Position | Passes Required | Travel Speed (ipm) | AC (amp) | Cup Diameter (in) | Cup Size | Gas Flow (cfh) | Gas Volume per 100 ft of weld (cft) | Tungsten Diameter (in) | Filler Rod Diameter (in) | Pounds Deposited per 100 ft (lb) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1/16 | Flat | 1 | 8 | 80 | 1/2 | 8 | 20 | 50 | 1/16 | 3/32 | 1/2 |
| 1/16 | H & V | 1 | 8 | 80 | 3/8 | 6 | 20 | 50 | 1/16 | 3/32 | 1/2 |
| 1/16 | Ovhd | 1 | 8 | 70 | 3/8 | 6 | 25 | 62 | 1/16 | 3/32 | 1/2 |
| 1/8 | Flat | 1 | 10 | 150 | 1/2 | 8 | 20 | 40 | 1/8 | 1/8 | 2 |
| 1/8 | H & V | 1 | 8 | 120 | 3/8 | 6 | 20 | 50 | 3/32 | 1/8 | 2 |
| 1/8 | Ovhd | 1 | 8 | 135 | 3/8 | 6 | 25 | 62 | 3/32 | 1/8 | 2 |
| 3/16 | Flat | 1 | 8 | 215 | 3/4 | 12 | 25 | 62 | 5/32 | 5/32 | 4.5 |
| 3/16 | H & V | 1 | 8 | 180 | 1/2 | 8 | 25 | 62 | 1/8 | 5/32 | 4.5 |
| 3/16 | Ovhd | 1 | 8 | 190 | 1/2 | 8 | 30 | 75 | 5/32 | 5/32 | 4.5 |
| 1/4 | Flat | 1 | 8 | 260 | 3/4 | 12 | 30 | 75 | 3/16 | 3/16 | 7 |
| 1/4 | H & V | 1 | 8 | 235 | 3/4 | 12 | 30 | 75 | 3/16 | 3/16 | 7 |
| 1/4 | Ovhd | 1 | 8 | 240 | 3/4 | 12 | 35 | 87 | 3/16 | 3/16 | 7 |
Recommended Shielding Gases
- Linde HeliStar™ A-75 (25% Helium/75% Argon)
- Linde Argon
TIG Welding Parameters for Stainless Steel
| Material Thickness (in) | Position | Passes Required | Travel Speed (ipm) | DCEN (amp) | Cup Diameter (in) | Cup Size | Gas Flow (cfh) | Tungsten Diameter (in) | Filler Rod Diameter (in) |
|---|---|---|---|---|---|---|---|---|---|
| 0.018 | Flat | 1 | 14 | 20 | 5/16 | 5 | 10 | 0.040 | 0.035 |
| 0.030 | Flat | 1 | 10 | 35 | 3/8 | 6 | 10 | 1/16 | 0.045 |
| 0.062 | Flat | 1 | 8 | 70 | 3/8 | 6 | 10 | 1/16 | 0.045 |
| 0.093 | Flat | 1 | 8 | 70 | 3/8 | 6 | 15 | 1/16 | 1/16 |
| 0.125 | Flat | 1 | 8 | 140 | 3/8 | 6 | 15 | 3/32 | 1/16 |
| 0.250 | Flat | 3 | 8 | 250 | 1/2 | 8 | 15 | 1/8 | 3/32 |
Recommended Shielding Gases
- Linde Helistar™ A-75 (25% Helium/75% Argon)
- Linde Hydrostar™ H-5
- Linde Argon
