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Tig Welding in Motorsport

The document discusses TIG welding techniques for motorsport applications. It begins with an overview of Lincoln Electric's company profile and motorsports program. Some key points covered include: - TIG welding is well-suited for motorsports due to its ability to produce high quality welds on a variety of exotic materials with precise control. - Parameters like welding current type (DC vs. AC), pulse settings, and basic features like upslope and downslope can be adjusted based on the material. - AC is recommended for aluminum to help break up the protective aluminum oxide layer during welding. - Advanced TIG techniques like pulse welding can reduce heat input and distortion when welding thin materials.

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0% found this document useful (0 votes)
92 views19 pages

Tig Welding in Motorsport

The document discusses TIG welding techniques for motorsport applications. It begins with an overview of Lincoln Electric's company profile and motorsports program. Some key points covered include: - TIG welding is well-suited for motorsports due to its ability to produce high quality welds on a variety of exotic materials with precise control. - Parameters like welding current type (DC vs. AC), pulse settings, and basic features like upslope and downslope can be adjusted based on the material. - AC is recommended for aluminum to help break up the protective aluminum oxide layer during welding. - Advanced TIG techniques like pulse welding can reduce heat input and distortion when welding thin materials.

Uploaded by

eyadbj
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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TIG WELDING in MOTORSPORT

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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design. 1911: Manufacturing the first portable welding machine with variable voltage in the world.

Founded in 1895 by John C. Lincoln 1895: Producing first Electric Motors of Lincolns own

Company Profile

2006 : The global Leader in Design, Development and Manufacture of Arc Welding Products, Plasma Cutting, and Robotic Welding Systems
1.8 Billion $ Worldwide Turnover Over 7,000 Worldwide Employees 33 Manufacturing Sites in 19 Countries Representation in over 160 Countries

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Lincoln is the industry leader with product offerings, including: Equipment : Stick welders TIG welders MIG welders Plasma cutting Engine Driven welders Robotic/Automation systems Environmental systems Consumables : Mild steel Low alloy steel Stainless steels Non-ferrous Hardfacing applications

Innovative Technology

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Lincoln Electric in Europe

Production and Sales Locations

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Enhance Image of Lincoln in Motorsport world Drive Technology with car race team Create Brand Awareness Main elements Safety Performance Ease Accessibility Partnership

Motorsports Program

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Officially Licensed Product of NASCAR - 2009 Contingency Sponsor of NASCAR Busch, Grand National and Weekly Racing Series - 2009 NASCAR Technical Institute - Curriculum NASCAR Research Center Involvement Official Welder of the Indy Racing League Official Welder of the Infiniti Pro Series Official Welder of USAC - 2009 Official Supplier to ARCA Re/Max Series - 2009 Series Sponsor ARCA Lincoln Welder Truck Series Major Contingency Sponsor of NHRA Award presenter for the Toyota Atlantic Series Presenting Sponsor of the Valvoline Cup Contingency Connection

Present Involvement in USA

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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What is TIG (or GTAW) Welding ?


Gas Tungsten Arc Welding Water IN (Cold)

GTAW PROCESS

Welding Current TIG Torch Ceramic Cup Shielding Gas IN Tungsten Electrode Arc Welding Rod Base Material
Water Out (Hot)

Shielding Gas (Ar or Ar/He) Shielding Atmosphere Solidified Weld Metal

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TIG Welding in Motorsport


WHY TIG Excellent quality of weld with low porosity WELDING ? Welds made with or without filler metal Precise control of welding variables Precise welding on complex piece Low amperage to weld on thin materials Visually Appealing, no spatters, nice ripples Weld all kind of exotic material used in Motorsport (Aluminium, Titanium, Chromolybdenum, magnesium...) Ideal process for frequently starts / stops and short welds Limitations : Requires greater welder dexterity, low deposition rate, more costly on thick sections

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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How to select the Welding Current ?


Steel Stainless Steel Titanium Copper Nickel Alloys Welding Current

Why DC- ?
High energy level at High energy level at the welding puddle the welding puddle Low energy at the tip Low energy at the tip of the electrode (sharp) of the electrode (sharp)

DC-

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How to select the Welding Current ?


Welding Current Aluminium Magnesium

Why AC ?

AC
Aluminum has a melting Aluminum has a melting point less than 700C point less than 700C Aluminum oxide on the Aluminum oxide on the surface has a melting surface has a melting point above 1800C point above 1800C Reverse polarity, half of Reverse polarity, half of the AC arc, breaks and the AC arc, breaks and clean the oxide skin clean the oxide skin ahead of the weld ahead of the weld

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Why AC ?

Typical Sinusoidal changes polarity gradually Square Wave changes polarity + instantly for smoother and stable arc + The AC TIG processes is using the positive period for cleaning ALU Oxide The Negative period is used for welding. (penetration) As a result: The process efficiency of AC TIG is low as only a part of the period is used for welding Need to optimize Welding by
Cleaning before welding adjusting Balance AC

WHY AC on ALUMINIUM ?

Cleaning

Welding
Balance AC

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TIG AC vs TIG DC-

The thermal conductivity of Aluminum compared to Stainless is 12 times higher. We need more energy for the Stainless sheet welding: same volume of Aluminum Most used tungsten 1.6 mm The process efficiency is lower Setting approx.. 25>30Amps/mm because of the AC wave form Conclusion: We need much more energy (Welding Amps) to weld the same plate thickness.

AC TIG Aluminum versus DC TIG Stainless

Aluminum sheet welding: Most used tungsten 2.4 mm Setting approx.. 30>40Amps/mm

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The Argon TIG arc is spread from itself. As a result the energy per surface is low. Concentrating the arc on a smaller surface with the same welding current will increase energy per mm Increasing the AC Arc frequency will focus the arc. Concentrating the heat on a smaller surface will: Reduce the welding current increase the travel speed reduce the heat input/cm
>> less distortion

Feature: AC frequency

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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LIFT TIG strike mode


3 2

1. Bring slowly the TIG Features torch electrode on the work piece. 2. Press the trigger of the TIG torch. 3. Lift the electrode from the work piece to start the TIG arc.

Basic

Electronic device minimizes short circuit current before starting. Electrode wear and tungsten inclusions in the weld pool are considerably reduced compared to Scratch start. Used for :
Occasional TIG welding TIG Welding when using appliances sensitive to electromagnetic interference like electronic on racing cars.

For excellent TIG welding everywhere, anywhere !

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HF TIG strike mode

1. Bring slowly the electrode at 2 to 4 mm from the work piece. 2. Press the trigger of the TIG torch. 3. High Frequency spark ignites the arc.

Basic Features

Advantages :
The electrode doesn't touch the piece. No risk of tungsten inclusion in the weld. No wearing of the tungsten electrode tip

2 to 4 mm

Used for :
For outstanding and professional TIG welds

High metallurgical quality TIG Welding Precision TIG Welding

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Start Current

Basic Features

Hot / Soft Start

Soft Start on Steel and Stainless steel to avoid burn through

Aluminum is an excellent conductor of heat. The welding of aluminum requires Hot start always.

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Upslope
After the arc starting sequence, current goes from Start level to welding current value

Basic Features

Upslope

Weld pool formation is facilitated.

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Welding Current
Weld Current

Basic Features

Weld current can be adjusted while welding to control heat input

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Downslope
At the end of the weld, the current gradually decreases from Welding value to Crater level

Basic Features
Downslope

End of welding is optimized

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Crater Current
Can be useful in some applications in order to better finish the weld pool and avoid final crater.

Basic Features
Crater Current

Final Crater is avoided to prevent cracking

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Trigger mode : 2 steps

4 steps

Basic Features

Control the heat input with one push button

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Postflow Gas Control This enables the


weld pool to cool down under protected atmosphere.

Basic Features

Postflow

It protects the weld pool and tungsten electrode from oxidation

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What is TIG PULSE ?


The welding current blinks between two set values: Peak current Background current The average gives less heat applied to the piece It is ideal for welding thin plates. It helps the operator to control the welding process and obtain more uniform, precise and attractive weld beads.

Advanced Features

Less heat means less distortion !

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Pulse parameters :
Frequency :
Normal Pulse welding in a frequency range between 0,2 to 20 Hz.

Advanced Features
Peak = Preset current

Background Current :
It is the current during the low portion of the pulse waveform. It can be adjusted from 10% to 90% of the welding (peak) current.

Frequency On-time

On-time Control :
Adjust the peak pulsing on-time. The on-time can be adjusted from 10% to 90% of the pulsing period.

Shape it the way you want it !

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Pulse parameters :

Advanced Features

Pulse Frequency

Time in

Background Current

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High Speed Pulse


Pulsing above 100Hz and up to 300500Hz means High Speed Pulsing. You cant see the arc blinking any more, however the arc is pulsing. The arc is more concentrated (focused). The heat altered zone is smaller Distortion is decreased. Welding speed is higher (compared to normal TIG process).

Advanced Features

Focus on energy and speed !

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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TIG DC Applications
To select max Power of the TIG DC machine, Check : Plate Thickness to be welded Input power available on site

Selection Chart

Tungsten electrode diameter

230V 1 phase

400V 3 phases

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TIG AC Applications
To select max Power of the TIG AC/DC machine, Check : Plate Thickness to be welded Input power available on site

Selection Chart

Tungsten electrode diameter

230V 1 phase PFC

400V 3 phases

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How to get max. out of 230V plug ?


Most of TIG applications are done on site where we have 230V / 1phase available The max current available from Power Network at 230V is limited at 16A with a slow blow fuse The maximum welding amperage reachable with traditional inverters is max 160A Machines welding on Aluminum need a higher amperage & efficiency to perform Power Factor Correction is the way to maximize the output at 230V 16A and be able to reach 200A welding output

What is PFC ?

V205T AC/DC featuring PFC Technology

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Lincoln Electric Company Profile


Lincoln Electric Motorsport program

Index

What is TIG Welding ?


Why TIG Welding in Motorsport applications

How to select the Welding Current ? DC or AC ?


TIG AC Advanced Features

TIG Basic Features


Lift TIG / HF TIG / Upslope, Downslope / Postflow / Start, Crater / What is TIG Pulse / Why High Speed Pulsing ?

How to select the right power source ? Conclusion & Questions ?

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Conclusion
Choose TIG welding for high quality welds on all kind of materials Use ALtenartive Current for Aluminium, DC for the rest of materials
Clean Aluminium plate and adjust balance to optimise AC welding efficiency Play on AC frequency to focus the arc and minimise distortion

CONCLUSION & QUESTIONS

Recommended Lift TIG striking mode when welding on car frame, and HF for excellent striking Play with Higher Hot Start and long up-slope to preheat Aluminium plate, long down-slope & lower crater level to avoid shrinking cracks Use Pulse to control the heat input and High Speed Pulse to focus the arc and minimise distortion Select the right machine for the right application (material to be welded, max thickness, input power availability)

QUESTIONS ?

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