TIG Welding

(GTAW)
Terms

• TIG stands for Tungsten Inert Gas

• Technically called Gas Tungsten Arc Welding or

GTAW
Arc Welding

• Process that is used to join metal to metal by using

electricity to create enough heat to melt metal.

• Melted metals when cool result in a binding of the

metals
Flux And Shielding Gas

• To protect the weld area from oxygen, and water

vapour.

• Depending on the materials being welded, these

atmospheric gases can reduce the quality of the
weld or make the welding more difficult.

• Improper gas can cause porous and weak weld.

TIG Welding

• Arc welding Process that uses a non-consumable

tungsten electrode to produce the weld.

• Weld area is protected from atmospheric

contamination by an inert shielding gas.

• A filler metal is normally used.

TIG Welding Requirements

• Requires 3 things, Heat, Shielding, and Filler metal.

• Heat is produced by electricity passing through the

tungsten electrode by creating an arc to the metal.

• The shielding comes from a compressed bottle of gas.

• The filler metal is just a wire that is dipped by hand into

the arc and melted
Process
• The welder turns on the gas flow by a valve on the TIG
torch.
• The torch is held over the weld joint just far enough for
the torch not to touch the metal.
• Then the welder presses a foot pedal and the TIG
torches tungsten electrode starts an arc.
• Once the arc is started the two pieces of metal begin to
melt by creating a puddle of metal.
• Once the puddle is established the welder with the
other hand starts filling the joint by manually dipping a
welding wire into the arc to fill the joint.
Components Of TIG Welder
• Main TIG welder components are,
• TIG Power Supply
• TIG Torch
• Shielding gas
 TIG Power Supply

• Usually welding power supplies which supplies

constant current.
• “High frequency start” eliminates the need to
physically strike an arc like SMAW by creating a
brief moment of high voltage.
• Pre-flow and post-flow feature confirms the
protection of the weld by supplying shielding gas
before and after the weld is performed.
• Frequency settings help the characteristics of the
welding arc.
TIG Welding Voltage Type and
Welding Polarities
• Both AC and DC currents are used.
• D/C electrode (-) negative concentrates about 2/3
of the heat onto the metal welded.
• This produces a deep penetration weld.
• D/C electrode (+) positive concentrates about 2/3
of the heat onto the electrode.
• This produces a shallow weld.
TIG Torch
• Torch consists various electrodes, cups, collets and
gas diffusers.
• Basic torch types are
• Air cooled torch which is least expensive
• Water cooled torch which is most efficient.
• As the name main ingredient is tungsten in the
electrode.
• Pure tungsten
• Zirconium Tungsten
• Thorium tungsten
Tungsten Electrode
• Create the arc for TIG welding.
• Tungsten properties allows an arc to maintain a
temp up to 11 000oF.
• Electrode diameter is vary 1/16 to ¼ of an inch.
• Most critical component of the process is shape of
the tip of the electrode.
• Pointed tip – welding ferrous metals.
• Rounded and Tapered ball end – welding non-ferrous
metals.
Shielding Gas
• Necessary to protect welding area from
atmospheric gases which can cause fusion defects,
porosity and weld metal embrittlement.
• Also transfers heat from the tungsten electrode and
helps start and maintain a stable arc.
• Most of cases pure Argon is used.
• Argon-Hydrogen, Argon-Nitrogen, Argon-Helium
mixtures are also used.
• Ar-He typically used on thicker metals to get deep
penetration.
USES
• Most commonly used to weld thin sections of
stainless steel, steel and non-ferrous metals such as
Aluminum, Copper Nickel alloys, Magnesium,
Titanium.
• Combinations of dissimilar metals also TIG welded
such as Copper to Everdur, Copper to Stainless
Steel, Nickel to steel and Stainless Steel to Cast
iron.
Advantages
• Works on almost all types of metals with higher
melting points. Specially for reactive metals like
titanium and zirconium, which dissolve oxygen and
nitrogen and become embrittled.
• Accuracy and control. The process provides more
precise control of the weld than any other arc
welding process, because the arc heat and filler
metal are independently controlled.
• Good looking weld beads
• Very good for joining thin base metals because of
excellent control of heat input.
• Creates strong joints. It produces top quality welds
in almost all metals and alloys used by industry.
• Clean process with minimal amount of of fumes,
sparks, spatter and smoke i.e. minimal finishing
required.
• Works in any position.
• Because the electrode is non-consumable, the
process can be used to weld by fusion alone
without the addition of filler metal.
Disadvantages
• Brighter UV rays when compared to other welding
processes
• Slower process than consumable electrode arc
welding processes.
• Takes practice (Difficult Process)
• More expensive process overall. Expensive welding
supplies (tungsten Electrodes and Shielding gases)
• Not easily portable.
• Transfer of molten tungsten from the electrode to
the weld causes contamination. The resulting
tungsten inclusion is hard and brittle.
• Exposure of the hot filler rod to air using improper
welding techniques causes weld metal
contamination.
 Introduction to SAW

 Submerged arc welding (SAW) is a method in which

the heat required to fuse the metal is generated by
an arc formed by an electric current passing between
the electrode and the work piece

 There is no visible arc and no sparks, spatter or

fume. The electrode may be a solid or cored wire or
a strip.

 SAW is normally a mechanized process.

Submerged Arc Welding ( Images )
 Process of SAW
 The molten weld and the arc zone are protected from
atmospheric contamination by being "submerged" under a
blanket of granular fusible flux.
 flux consists of lime, silica, manganese oxide, calcium
fluoride, and other compounds.
 When molten, the flux becomes conductive, and provides a
current path between the electrode and the work.
 This thick layer of flux completely covers the molten metal
thus preventing spatter and sparks as well as suppressing
the intense ultraviolet radiation and fumes that are a part
of the shielded metal arc welding (SMAW) process
Process of Saw
 Features of SAW

 Flux Hopper : It stores the flux and controls the rate

of flux deposition on the welding joint.
 Welding head : It feeds flux and filler metal to the
welding joint. Electrode (filler metal) gets energized
here
 Flux : The granulated flux shields and thus protects
molten weld from atmospheric contamination. The flux
cleans weld metal and can modify its chemical
composition also.
 Features of SAW

 Electrode : SAW filler material usually is a standard wire

as well as other special forms. This wire normally has a
thickness of 1.6 mm to 6 mm (1/16 in. to 1/4 in.). In certain
circumstances, twisted wire can be used to give the arc an
oscillating movement. This helps fuse the toe of the weld to
the base metal. The electrode composition depends upon the
material being welded. Alloying elements may be added in
the electrodes. Electrodes are available to weld mild steels,
high carbon steels, low and special alloy steels, stainless
steel and some of the nonferrous of copper and nickel.
 General Operating Conditions

 Current: the total welding current can range between

100 and 3600 amps.

 Wires in one molten pool: from 1 to 6.

 Voltage: 20-50 volts.

 Speed: 30-350 cm/min.

 Deposition rate: 2-100 kg/hr.

 Types of SAW

Submerged Arc Welding can be divided into 5 types:

 Single Wire
 Twin Wire
 Tandem
 Tandem Twin
 Multi Wire
 Single Wire

• Single wire welding is

the most widely used
SAW method.
• DC power source is
used.
• The solid or cored
wires of diameter 2.0-
4.0 mm are used.
• A small diameter
produces a higher
deposition at the same
rate.
 Twin Wire

• For twin wire welding,

two wires are connected
to the same power
source.
• DC power source is
used
• It offers up to 30%
higher deposition rates
and can be used at
higher currents and
speeds.
• Very high welding
speeds can be achieved
in fillet welding.
 Tandem

• In tandem sub-arc
welding each of the two
wires is connected to its
own power source and fed
simultaneously by its own
feed unit.
• Both AC and DC source
can be used.
• The wires are normally
large diameter (3.0-5.0
mm) and deposition rates
are about twice that of
single-wire welding.
 Tandem Twin

• The ESAB tandem-twin

process involves two twin
wire heads placed in
sequence.
• Both AC and DC source
can be used.
• With the use of 4x2.5
mm diameter, wires
deposition rates of up to
38 kg/h can be achieved
 Multi-Wire

• Up to six wires can be used

together, each with their
own power source.
• The lead wire is usually
DC+ polarity with the
trailing wires being AC.
• Speeds of up to 2.5 m/min
can be achieved giving a
maximum deposition rate of
90 kg/h.
• This technique is
particularly suitable for
longitudinal pipe welding
 Advantages of SAW
 High quality

 Little risk of undercut and porosity

 No spatter

 Very little risk of lack of fusion due to deep and safe

penetration

 High deposition rate

 Advantages of SAW

 High thermal efficiency

 No radiation
 High welding speeds are possible
 Deep penetration rate
 Low distortion
 Limitations of SAW

 Precise joint preparation required

 No observation of arc and process during welding is

possible

 High operational effort

 It can not be used for plates less than 5mm thickness

 Limitations of SAW

 Flux is subjected to contamination and adsorbtion of

moisture.

 Solidification cracking.

 Irregular wire feed.

 Applications of SAW

 Fabrication of Boiler Pressure Vessel.

 Railroad tank cars.

 Structural shapes and cylinders.

 Circular welds.

 Beam Production.
 Applications of SAW

 Ship Building.

 Circumferential welding in wind tower fabrication.

 Longitudinal pipe welding

 Nickel-base Alloys

 Surface Applications
Resistance Welding
Resistance Welding

• A liquid state welding process

• Is a thermo-electric process
o Uses electric resistance to generate heat
Working Principal
• Heat is generated by passing current through a electric
resistance
• Amount of heat produced is depend on
o Resistivity of the material
o Surface conditions
o Current Supplied
o Time
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Types of RW

• Spot Welding
• Seam Welding
• Projection Welding
• Flash Butt Welding
• Spot Welding
• Simplest type of resistance welding
• Two copper electrodes with anvil faces

• Create a circular nugget ( 4-7 mm )

Seam Welding
• Also known as Continuous Spot Welding
• A roller type electrodes are used
• Create a continuous weld joint

• The time and movement of electrode is controlled

o Weld overlap and work piece does not get too hot
• Used to create air tight joints
Projection Welding
• Dimple is produced on work piece
• Flat electrodes
Flash butt Welding
• Used to weld tubes and rods in steel industries
• Work pieces are clamped in the electrode holders
• high pulsed current in the range of 100000 ampere
• Electrodes – One is Fixed and other is movable
Applications
• Resistance welding - automotive industries
• Projection welding - production of nut and bolt
• Seam welding - produce leak prove joint
required in small tanks,
boilers etc.
• Flash welding -welding pipes and tubes
Advantages
• It can weld thin (0.1 mm) as well as thick (20mm) metals.
• High welding speed.
• Easily automated.
• Both similar and dissimilar metals can be weld.
• The process is simple and fully automated so does not
required high skilled labor.
• High production rate.
• It is environment friendly process.
• It does not require any filler metal, flux and shielding
gases.
Disadvantages
• High equipment cost.
• The thickness of work piece is limited due to current
requirement.
• It is less efficient for high conductive materials.
• High electric power required.
• Weld joints have low tensile and fatigue strength.
Metal Inert Gas (MIG) Welding
Contents
• What is MIG welding?
• MIG Welding process
• Schematic Representation of MIG Welding
• Applications of MIG Welding in Manufacturing
• Advantages of MIG Welding
• Disadvantages of MIG Welding
What is MIG Welding ?
• It is also known as Gas Metal Arc Welding.
• It is a high- deposition rate welding process.
• The metal wire is fed from a spool.
• This is a semiautomatic welding process.
 MIG Welding Process
• Consists of a handle with trigger control to wire feed the spool to the weld
joint.
• MIG basically requires:
- Electricity to produce heat.
- An electrode to fill the joint.
-Shielding gas to protect the weld.
MIG Process contd..
Schematic Representation of MIG Welding
Welding Variables and Parameters
• Electrode extension
• Wire feed speed - amperage. Controls fusion and penetration.
• Travel speed - controls depth of penetration.
• Gas flow rate - protects weld from atmosphere.
• Voltage - set on the welding machine and controls the arc length.
• Tilt angle - back or fore hand should be not greater than 15° from the
perpendicular.
Applications of MIG in Manufacturing
• Automotive repair
• Overlay of resistant coating
• Welding pipes
• Rebuilding equipment
• Reinforce the surface of worn out railroad track.
Advantages of MIG Welding
• High quality welds can be produced much faster
• Since a flux is not used, there is no chance for the entrapment of slag in the
weld metal resulting in high quality welds
• The gas shield protects the arc so that there is very little loss of alloying
elements. Only minor weld spatter is produced
• MIG welding is versatile and can be used with a wide variety of metals and
alloys
• The MIG process can be operated several ways, including semi and fully
automatic
Disadvantages of MIG Welding
• Cannot be used in the vertical or overhead welding positions because of the
high heat input and the fluidity of the weld puddle

• The equipment is complex

Friction Welding
 Introduction
Friction welding is a solid state
joining process that produces
coalescence by the heat
developed between two surfaces
by mechanically induced surface
motion.

•It is solid state joining process.

•Mechanical friction between a
moving work piece and a stationary
component.
•Lateral force (upset) is applied to
plastically displace and fuse the
materials
 Types of Friction Welding
Spin
Welding:
A rotating chuck
along with flywheel.
After reaching to
required speed motor
is removed from
flywheel.
Linear
Friction
Welding:
Oscillating Chuck is
used.
Use for non-round
shapes as compare
to Spin welding.
Material should be of
high shear strength.
Friction
Surfacing:
It is a surface coating
process.

Coating material
Mechtrode is rotated
under pressure over
substrate.
Friction Stir
Welding:
A cylindrical shouldered tool,
with a profiled probe (nib or
pin) is used.

Friction is between tool

shoulder, nib and work metal.
Advantages of Friction Welding
•Simplicity of operation and simple equipment.
•Less time requirement.
•Low Surface impurities and oxide films.
•Compare to resistance butt welding produces improved welds at higher
speed and lower cost, less electric current is required.
•Heat affected zone is small as compare to conventional flash welding.
•Less shortening of the component, as compared to that in flash or butt
welding.
•There is no flux, gas, filler metal or slag present to cause imperfections in
welds.
Disadvantages of Friction
Welding
•Process is restricted to flat and
angular butt welds.
•Use only for joining small parts.
•In case of tube welding process
becomes complicated.
•In case of high carbon steels it is
difficult to remove flash.
Friction Welding Machine
•It require heavy rigid machine due to
high Thrust pressure.
Applications:
•Automobile: Bimetallic engine valve, universal joint yoke,
gear hub etc.
•Aerospace: Turbine blade joining, seamless joining etc.
•Consumer: Hand tools, sports equipment
•Industrial: Spindles, tapers, tools
•Military
•Medical: Stainless steel joining of containers
•Marine: Shipping Industry
•Mining/Drilling: Twist drill etc.
•Hydraulic equipments
 INTRODUCTION

Electro slag welding is a type of arc welding wherein the

coalescence is produced by molten slag which melts the filler
metal metal and the surface of the work to be welded, electro
slag welding is quite similar to vertical submerged arc welding.
 WOKING PRINCIPLE

1. In electro slag welding process a granular flux is placed in the gap

between the plate being welded and as the current is turned on, welding
takes place in a water-cooled copper shoes that bridge the gap of the joint
as the flux melts, a slag blanket from 25.4 to 38.1 mm thickness is
formed , high resistance of the slag causes most of the heating for the
remainder of the weld thus electro slag welding is a progressive process of
melting and solidification from the bottom to upward.
2. The maximum thickness that can be weld by this process is up to 100 mm
3. Molten metal and slag are retained in the joint by means of copper shoes
that automatically move upward as the weld progresses by means of a
temperature sensitive mechanism.
 ADVANTAGES

1. Joint preparation is quite simple as compared to other

welding processes.
2. Very high thickness plate can be very easily welded in a single
pass more economically .
3. It gives extremely high deposition rate.
4. Distortion and thermal stresses are in very low percentage.
5. Flux consumption is very low.
 DISADVANTAGES

1. Process is only limited to vertical position.

2. Electro slag welding tend to produce rather large grain size.
3. Complex shape joint cannot be welded by this process.
4. More chances of hot cracking and notch sensitivity in the heat
affected zone.
 definition

 Atomic hydrogen welding (AHW) is an arc welding

process that makes use of an arc between two
tungsten metal electrodes within an atmosphere
composed of hydrogen. Shielding is obtained from
the hydrogen.
 The electric arc produced in the process efficiently
breaks up the molecules of hydrogen that later
recombine through an extreme release of heat.
 Equipments and Parameters required
in AHW
2 tungsten electrode.
Hydrogen gas cylinder with regulator and hose.
Electrode holder or torch.
300 V AC power supply machine with controller.
Filler rod if needed.
Operation Of AHW
 The equipment consists of a welding torch with two
tungsten electrodes inclined and adjusted to maintain a
stable arc.
 Annular nozzles around the tungsten electrodes carry the
hydrogen gas supplied from the gas cylinders.
AC power source is suitable compared to DC,
because equal amount of heat will be
available at both the electrodes.
A transformer with an open circuit voltage of
300 volts is required to strike and maintain the
arc.
The work pieces are cleaned to remove dirt,
oxides and other impurities to obtain a sound
weld. Hydrogen gas supply and welding
current are switched ON.
 An arc is stuck by bringing the two tungsten electrodes in
contact with each other and instantaneously separated
by a small distance, say 1.5 mm, such that the arc still
remains between the two electrodes.
 As the jet of hydrogen gas passes through the electric
arc, it disassociates into atomic hydrogen by absorbing
large amounts of heat supplied by the electric arc.
H2 = H + H – 422KJ (endothermic reaction)
 Recombination takes place as the atomic hydrogen
touches the cold work piece liberating a large amount of
heat.
H + H = H2 + 422 KJ (Exothermic reaction)
 What to avoid in AHW

 Too little heat or too much heat according to material to

be weld. Too little heat is indicated if too much time
required for fusion.
 Arc gap should not be too small or large otherwise very
less heat will be released.
 Less heat causes small pool, difficult to maintain, surface
porosity and it solidify fast and uneven.
 Too much heat should be avoided otherwise wide pool
and hole will form in weld material.
If heat and arc is correct then also proper fusion
doesn’t occur then reduce the welding speed or
the current setting should be increased.
To weld delicate metals, arc distance should be
less so to weld with less heat.
Distance between weld metal and arc should be
avoided. Arc should touch the weld metal.
 Successful welding in AHW depends on

 Size of the arc.

 Contact of the arc with the work.
 Speed of travel.
 Current setting.
 Advantages of AHW

 Intense flame is obtained which can be concentrated at

the joint. Hence, less distortion.
 Work piece do not form a part of the electric circuit.
Hence, problems like striking the arc and maintaining
the arc column are eliminated.
 Separate flux / shielding gas is not required. The
hydrogen envelop itself prevents oxidation of the metal
and the tungsten electrode.
 Welding is faster.
 The average temperature of the flame is approximately
4000 deg. C., This is the third hottest flame
after dicyanoacetylene at 4987 °C and cyanogen at
4525 °C.
 Hydrogen gas flows by the tungsten electrodes in the
holder, keeping them cooler and lengthening the
electrode life.
 An automatic atomic - hydrogen welding process has
also been developed in which, instead of using
hydrogen from high-pressure cylinders, the hydrogen is
obtained by cracking anhydrous ammonia.“
 The heat produced by this torch is sufficient to
weld tungsten (3422 °C), the most refractory metal.
 Filler material is not used. In fillet weld only, filler is
used. Or in other material if to have any change in
composition of weld.
 Hydrogen supply and arc can be easily controlled by
welder so because of that heat is controlled to weld
different metals.
 Because of the powerful reducing action of the atomic
hydrogen, alloys can be melted without fluxes and
without surface oxidation.
 limitations
 Cost of welding by this process is slightly higher than
with the other process.
 Welding is limited to flat positions only.
 Because of the high levels of heat produced in this
welding process, welders need to be even more aware
of the dangers they are exposed to.
 Skilled welder is required.
 Due to advances in inert gases AHW may be limited.
 Hydrogen is highly inflammable gas so it should be
taken care.
 Applications of AHW
Atomic hydrogen welding is used in those
applications where rapid welding is necessary,
as for stainless steels and other special alloys.
For most of the ferrous and non ferrous
metals.
For thick as well as thin sheets or small
diameter wires (2-10mm).
Can be applied almost to any metal, specially
in light gauge metal, special ferrous alloys, and
most non ferrous metals and alloys.
Thank you