What is Tungsten Inert Gas (TIG) Welding Process : Introduction, Working Principle, Equipment's of TIG, Process Parameter, Application, Advantages, Disadvantages

History of TIG Welding Process:-

In the 1940s, TIG welding was first  made by a welder named Russell Meredith who is working  for Northrop Aircraft Corporation in Southern California. He made the strategy in light of the fact that the strategies for the day were insufficient for welds on aluminum and magnesium compounds.

 The patent for the interaction was bought by the Linde Division of Union Carbide, and the organization created and sold different lights, parts, and consumables for the procedure until the 1960s and 1970s when their licenses on the cycle and TIG-related devices terminated.

Introduction:-

TIG tungsten inert gas welding process is an arc welding process that utilizes a non-consumable tungsten cathode to deliver the weld. Tungsten Inert Gas (TIG) welding well known as Gas Tungsten Arc Welding (GTAW).

The weld area is preserved from the atmosphere with a shielding gas typically Argon or Helium or occasionally a mixture of Argon and Helium.

Filler metal may also feed manually for accurate joining.

GTAW most frequently called the TIG welding process was matured during Second World War. With the advancement of the TIG welding process, the joining of challenging to weld materials e.g. Aluminum and Magnesium become possible.

The use of TIG nowadays has advanced to a variety of metals like mild steel, stainless steel, and high tensile steel, Al alloy, Titanium alloy.

Like different welding systems, TIG welding power sources have also enhanced from basic transformer types to the profoundly electronic controlled force source today.

 

Working of TIG Welding Process:-

• In the TIG welding process, a non-consumable tungsten electrode is used to join the workpiece.

• The weld area is protected against the atmosphere by an inert shielding gas (argon or helium), and a filler metal is often used.

• The power is equipped from the power source (rectifier), through a welding torch and is supplied to a tungsten metallic electrode that is fitted into the handpiece.

• An electric arc is then constructed between the tungsten metallic electrode and the workpiece using a constant-current welding power supply that produces energy and conducted across the arc through a column of extremely high ionized gas and metal vapors.

• The tungsten metallic electrode and the welding zone are preserved from the surrounding air by inert gas.

• Up to 20,000°C temperatures can be produced due to electric arc and this heat can be focused to fuse and join two different parts of the workpiece.

• The weld pool can be utilized to get the base metal together with or without filler material

• Schematic diagram of TIG welding and mechanism of TIG welding is shown in the figure.

 

TIG welding equipment consists of the subsequent elements:-

• Power Supply:  AC or DC  are the two main prime power source of TIG welding, but in each, the output is called a drooping, or stable current characteristic; are the voltage/welding current relationship delivers a stable current for a given power source setting.

• Torch: There are an ample variety of torch designs for welding, depending on the operations. Plans (Design) which have the on/off switch and current control in the handle are regularly liked to foot controls. Specific torches are accessible for mechanized applications, e.g. orbital and bore welding of pipes.

• Electrode: The electrode tip is typically ground to an angle of 60 to 90 degrees for manual welding, negligent of the electrode diameter. For mechanized applications as the tip find the shape of the arc and influences the insertion profile of the weld pool, consideration must be paid to consistency in grinding the tip and evaluating its condition between welds.

• Gas Shielding: A gas lens ought to be fitted among the torch nozzle, to make sure laminar gas flow. This will enhance gas protection for hypersensitive welding operations like welding vertical, corner, and edge joints and on curved surfaces. There is also a variety of nozzles are available, which assure different gas coverage. The nozzle's choice depends mainly on the electrode diameter and on the convenience, defined by the assembly to be welded.

• Protective Equipment's: A slightly darker/hazier glass should be utilized in the head or hand shield than that used for MMA welding.

 

Process Parameter of TIG:-

The parameters that have an effect on the standard and outcome of the TIG welding process are given below.

• Welding Current: Higher current in TIG welding will cause splatter and workpiece to become harm. once lower current setting in TIG welding cause protruding of the filler wire. generally larger heat affected space will be found for lower welding current, as high temperatures ought to applied for extended periods of your time to deposit a similar quantity of filling materials. the mounted current mode can vary the voltage so as to take care of a relentless arc current.

• Welding Voltage: Welding Voltage will be mounted or adjustable betting on the TIG welding equipment. A high initial voltage permits for simple area unit initiation and a bigger vary of operating tip distance. Too high voltage will cause massive variables in welding quality.

• Inert Gases: The selection of protecting gas depends on the operating metals and effects on the welding price, weld temperature, arc stability, weld speed, splatter, conductor life, etc. It conjointly affects the finished weld penetration depth and surface profile, porosity, corrosion resistance, strength, hardness, and crispness of the weld material. a chemical element of atomic number 2 is also used with success for TIG welding applications.

• Welding Speed: Welding speed is a very important parameter for TIG welding. If the welding speed is inflated, power or heat input per unit length of the weld is decreasing, so less weld reinforcement results and penetration of attachment decreases. welding speed or travel speed is primarily the management of the bead size and penetration of the weld. it's dependent on current. Excessive high welding speed decreases wetting action, will increase the tendency of undercut, consistence, and uneven bead shapes whereas slower attachment speed reduces the tendency to consistency.

 

Advantages of TIG Welding Process:-

The advantages of tungsten inert gas welding are as follows:

• High-quality welds for suitable applications.

• No spatter because no filler metal through an arc.

• No flux cleaning.

• No flux is required.

• Suitable for welding of very thin sections.

• The versatility of the method.

• Non-corrosive and ductile joints.

• Less amount of flames and spark.

• Can be done both automatically and manually.

 

Disadvantages of TIG Welding Process:-

The disadvantages of tungsten inert gas welding are as follows:

• Generally slower the process.

• More costly than consumable electrode AW processes.

• More complicated to operate.

• Skilled and Professional workers are required.

• Labors are exposed to high intensity of light which can cause eye damage.

• Cannot use to weld thicker sheets of metal.

Application of TIG Welding Process:-

•  Stainless steel and non-ferrous metals like metal, magnesium, and copper alloy.

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