TECHNICAL UPDATE TE Andersen Consulting.
TIG Welding
By Leif Andersen, TE Andersen Consulting.
This article will provide the basics for TIG welding and its consumables including advantages and
disadvantages, where this process can be used, and how to properly set up a welding power source
for TIG welding.
Most vessels will have an electric arc welding machine onboard that can perform Manual Metal Arc
Welding (MMAW), also referred to as stick electrode welding. It is quite common that these machines
will also be fitted with a mode nob that can switch the machine over to perform Tungsten Inert Gas
(TIG) welding.
TIG Welding
Tungsten Inert Gas (TIG) welding (also referred to as Gas Tungsten Arc Welding GTAW) is a process
where heat is produced by an electric arc that is struck between a Tungsten (Wolfram) electrode and
the work piece. The arc and the electrode are shielded by an inert gas (usually Argon) that also
surrounds the weld pool and prevents oxidation. TIG welding can be performed using Direct Current
(DC) or Alternating Current (AC) welding current.
Argon cylinder with
regulator
Arc welding machine
set up for TIG welding Welding
Machine
Return cable with
return clamp
TIG torch
Welding technic:
Point the torch
slightly in the
direction of travel.
Tungsten electrode
Arc
Welding Rod
Argon shielding gas
Molten pool
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TECHNICAL UPDATE TE Andersen Consulting.
The TIG Torch
The TIG torch consist of the following parts:
1 Long back-cap
2 Heat shield
2 3 Collet 1,6mm - 2,4mm – 3,0mm
4 Collet body 1.6mm - 2,4mm – 3,0mm
Alternative: Gas Diffuser 1,6mm - 2,4mm - 3,0mm
5 Alumina nozzle 6, 7, 8
6 6 Tungsten electrode 1.6 mm - 2,4mm – 3,0mm
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When changing Tungsten electrode from 1,6mm to 2,4mm or 3mm it is also necessary to change
Collet and Collet body to 2,4mm or 3mm and vice versa.
The reason for using Tungsten is that it has a very high melting point of 3000 OC (5432OF). They are
normally in two different diameter sizes, 1,6mm (1/16″) and 2,4mm (3/32″). For aluminum a 3,0mm
(1/8″) tungsten electrode will be useful. During TIG welding the tungsten electrode will not melt despite
very high temperatures, but it will gradually be consumed during ignition and to some extent during
actual work. This is referred to as the burn-off rate. In time, it will be necessary to regrind the
electrode. In order to extend their capacity and performance the manufacturers alloy in any of the
following elements: Cerium (Ce), Lanthanum (La), Zirconium (Zr), Yttrium (Y) or Thorium (Th).
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)
)
1) Alloying elements in the form of oxides
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TECHNICAL UPDATE TE Andersen Consulting.
NB. Thoriated TIG welding electrodes with 2% thorium oxide (color code red) are currently the most
widely used electrodes worldwide. Thorium is however a radioactive element and as such represents
a potential danger to health and environment. Thorium is a so-called “a-emitter,” but when enclosed in
a tungsten matrix, the “a” radiation emitted externally is negligible. The danger to the welder arises
when thorium oxide gets into the respiratory canals. This problem can occur during welding (vapors)
as well as when grinding the electrode tip (grinding dust).
Tungsten electrode preparation
For Direct Current (DC) Electrode pointed
Radial grinding direction result in a wandering arc with possible tungsten fragment braking of causing
tungsten inclusions in the weld deposit. Make sure to do lengthwise grinding. The marks do not restrict
the current flow and improves performance. Use a dedicated grinding disk for tungsten grinding only.
15O to 30O
1-4 times electrode diameter.
For Alternating Current (AC) Electrode rounded (ball shape) First grind the electrode in similar
manner as for DC preparation. Then
break the point. Place the electrode in
the TIG torch and ignite the torch
towards a copper plate. The AC arc
15O to 30O will after short time melt the tungsten
electrode into ball shape.
There are special grinding machines
1-4 times electrode diameter for tungsten electrodes available.
Meltback point
The ball should be equal to or slightly
larger than the electrode diameter at
the meltback point.
Adjust the tungsten to project from the alumina nozzle a distance of roughly 3-6mm.
The arc length should be
roughly equal to the
diameter of the tungsten
being used.
3-6mm 1-3mm
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TECHNICAL UPDATE TE Andersen Consulting.
Amperage setting
Use a 1,6mm (1/16″) tungsten electrode from 30 to 80 amps. Alumina nozzle size 6.
Use a 2,4mm (3/32″) tungsten electrode from 80 to 180 amps. Alumina nozzle size 7.
Use a 3,0mm (1/8″) tungsten electrode for anything above 180 amps. Alumina nozzle size 8.
The TIG torch should preferably be fitted
with a gas lens diffuser. A typical gas lens is
composed of a copper and or brass body with
layered mesh screens of steel or stainless steel
that helps evenly distribute the shielding gas
around the tungsten and along the weld puddle
and arc. Gas lenses can be used with all
shielding gases and are available for both air-
and water-cooled TIG torches. The most
durable gas lenses-feature a porous metal filter
that greatly improves laminar flow compared to
mesh screen designs.
Welding using Direct Current
TIG welding using DC current is relatively straightforward. The TIG torch needs a Lanthanum alloyed
tungsten electrode (color code gold) that is pointed and DC current with the torch connected to minus
polarity. With DC we can weld all metals including seawater resistant alloys like Cunifer and York Albro.
Only exception is aluminium and aluminium alloys.
DC
TIG welding using Direct Current
(DC) minus polarity the electrons
bombard the base material and melt
it.
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TECHNICAL UPDATE TE Andersen Consulting.
Welding using Alternating Current
Aluminium melts at 658 OC, the aluminium oxides melts at 2000 OC. If we use direct current – polarity
we are able to melt the aluminium but unable to break the oxide layer.
To better understand why, consider the following:
DC
TIG welding using Direct Current
(DC) minus polarity the electrons
bombard the aluminium melting it,
but are unable to break the oxides.
AC
TIG welding using Alternating
Current (AC) the polarity changes
from minus to plus. During minus the
electrons melts the aluminium,
during plus the electrons breaks up
the oxides.
With AC, during the half cycle when the electrode is positive and the workpiece is negative, the
electrons coming out from the base material break up the oxide layer: this action is known as cathodic
cleaning and is essential for successful welding of aluminium. So, it is necessary to use alternating
current or preferably square wave when welding aluminum.
The Tungsten electrode must have a round shape.
Fit the TIG torch with a pure tungsten (color code green) or with Lanthanum (color code gold)
electrode for aluminum welding if you have a non-square wave welding machine.
Fit the TIG torch with a Lanthanum (color code gold) tungsten electrode for aluminum welding if you
have a square wave welding machine.
The TIG torch should preferably be fitted with a gas diffuser (sintered metal) in order to avoid
turbulence in the shielding gas as it comes out of the TIG torch.
The TIG torch alumina nozzle must be size 8. This because the aluminum molten pool needs better
protection towards oxidation than steel or stainless steel.
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TECHNICAL UPDATE TE Andersen Consulting.
Use Argon as shielding gas. Set the flow rate on the regulator to 6 to 9 L/min. TIG welding is sensitive
to draft. If welding location is not sufficiently screened of the shielding gas can be insufficient and
create weld porosity.
Welding Machine requirements
There are 3 different ways of initiating the TIG torch, Scratch start, Lift Arc or High Frequency.
Scratch start is a very basic and simple process, usually found on low cost DC welding machines that
have been essentially designed for Manual Metal Arc Welding (MMAW) Stick electrode welding. The
TIG tungsten electrode is scratched on the workpiece to initiate the arc, and must be quickly lifted off
the workpiece to try prevent it sticking, but not lifted too far to avoid extinguishing the arc. Not a very
user-friendly process as the tungsten gets hot almost instantly as the arc is struck. Small bits and
pieces of the tungsten break off the electrode and get stuck in the weld deposit. This can cause
structural problems later.
With Lift-Arc Ignition feature, to start the arc the tungsten electrode is touched on the workpiece and
lifted off. The start-up current is very low and therefore the tungsten barely sticks to the workpiece and
the sharpened point is not damaged. Place and rest the alumina nozzle in a tilted angle on the ignition
location so that there is a gap of 2-3 mm between the tungsten electrode tip and the workpiece.
Gradually tilt up the welding torch until the tungsten electrode tip touches the workpiece. This will
trigger the lift arc function. Raise the torch and lift it into the normal position- the arc ignites and
increase in intensity to the set amperage. The machine senses that the contact is broken and begins
supplying full welding current. This creates little contamination and preserves the point on the
tungsten. It is still not 100% clean. The tungsten still can get contaminated. Lift start is a much
better option than scratch starting, for steel and stainless. But it is not a good option for aluminium
because of the affinity aluminium and tungsten have for each other.
Place and rest the 1) Tilt up the welding Raise the torch and
alumina nozzle in a torch until the lift it into the normal
tilted angle on the tungsten electrode position.
work piece. tip touches the work
piece. 2) Tilt the
torch back igniting
the arc.
2
2-3mm 1
Arc
Rest the alumina
nozzle on the work
piece.
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TECHNICAL UPDATE TE Andersen Consulting.
High Frequency (HF) ignition allows the operator to position the tungsten electrode near to the
starting point, and simply press the torch trigger to start the arc. The High Frequency start is a touch-
less method and creates almost no contamination unless the tungsten is ove r sharpened or the
amperage is turned too high at the start. It is the only acceptable choice for welding
aluminium. Unless you need to weld Aluminium, you don’t have to really have High Frequency start,
but it is nice to have for weld AC or DC if you have the option. HF is typically found on professional or
dedicated TIG welding machines, such as AC/DC TIG welders or higher end DC TIG machines. On
these machines, often the controls will allow the operator to choose between Lift-Arc or HF start. NB.
Please be aware that High Frequency can disturb radio communication on-board and also influence
on other electronic equipment.
Should the tungsten electrode be
contaminated by the pool or by the
consumable rod during welding it
will be necessary to regrind it. If
only slightly contaminated, keep a
copperplate at the worksite. Ignite
the electrode towards the
copperplate and let it burn for some
time. The electrode will gradually
clean itself toward the copper.
Remote control
After welding has progressed a while, much of this heat has moved ahead of the arc and pre-heated
the base metal to a temperature requiring less welding current than the original cold plate. If the weld
is continued further on to the end of the two plates where there is nowhere for this heat to go, it can
pile up and make welding difficult unless the current is decreased. Because of this the TIG torch
should be fitted with a hand amperage control so that the welder can gradually reduce the amperage.
It can also be that the joint figuration, edge preparation or welding position is varying, which will also
require a change of amperage. It will be an advantage if the TIG torch is fitted with a thumb control
amperage setting so that amperage can be increased or decreased during welding.
The remote control can be
incorporated into the TIG torch.
The remote control can also be added
to the torch by fastening with Velcro
straps.
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TECHNICAL UPDATE TE Andersen Consulting.
Another feature to consider is if the TIG torch should have a flexible head. This will for some
maintenance welding applications be an advantage. For giving better access in difficult working
situations the tungsten electrode can also be shortened and the long back-cap exchanged with a short
back cap.
Short back cap.
For maintenance welding an air cooled TIG torch will normally be sufficient. If extensive welding
considers a water cooled TIG torch.
Modern power sources for TIG welding can also have square wave configurations where both the
time proportions of electrode positive vs. negative and the relative intensities can be finely adjusted.
The effect is a more stable arc (than with simple AC), better penetration, and a more balanced heat
distribution between torch and workpiece.
This welding machine have a setting
for:
Manual Metal Arc Welding,
TIG DC lift arc,
TIG Square wave lift arc for Aluminium
and
Remote control.
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TECHNICAL UPDATE TE Andersen Consulting.
The shielding gas
Shielding gas is necessary for the TIG process. Argon and in some cases Helium can be used. This
gases which are chemically inactive (inert), has several functions in the TIG process:
• To provide the atmosphere needed for ionization, ensuring a stable arc and suitable heat transfer.
• To protect the hot tungsten electrode against the oxidizing effect of the air.
• To protect the molten pool against contamination and oxidation from the air.
• To protect the hot end of the filler metal rod from oxidation.
• To protect melt pool and electrode during cooling after the arc is broken.
The most commonly used shielding gas for TIG welding is Argon. The degree of purity should be at
least 99.95 %.
Common Argon qualities available:
Argon 4.0 Purity >= 99.99% Steel, Austenitic stainless steel.
Argon 4.8 Purity >= 99.998% Duplex stainless steel, Nickel alloys (6Mo), Aluminium.
Flow meter gauge
Cylinder gauge informing Informing flow rate
cylinder pressure in bar. in L/min. Flow rate
A full 50L argon cylinder should be from 6-9
will normally have a L/min.
pressure of 200bar.
Regulating knob
for setting flow
rate.
Argon cylinders
are painted grey.
Argon has proven to be the most suitable gas for shielding. It is a colourless and odourless inert gas,
heavier than air, non-toxic and nonflammable. It is obtained from air which contains approximately 1%
argon. For the TIG process, a quality 4.0 is commonly used. Duplex, Nickel alloys and aluminium will
requier quality 4.8. It is necessary to adjust the gas flow and a regulator with flow-meter is therefore
needed. Onboard a ship it is necessary to have a flow-meter that functions correctly also when
positioned out of vertical.
The argon flow will
lift the steel ball.
Read correct value
from underneath
the steel ball.
Use an additional flow meter to check that there is correct gas flow out of the torch. Do not trust the
flow meter on the cylinder regulator. There will normally be a drop in a long shielding gas hose.
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TECHNICAL UPDATE TE Andersen Consulting.
Surface preparation
Always remember that cleanliness of the work piece is a priority for first class TIG welding results.
Remove any oil, paint or other residue from the joint area. Then remove any oxide layer on the base
material. The surface must be metallically clean.
Welding procedure
Before welding starts, if a DC welding machine, check that the torch is connected to the negative (-)
polarity, and that sufficient gas is available from the gas supply. Open the argon cylinder valve and the
torch valve. If necessary, purge the gas system before setting correct gas flow on the regulator.
Check that the electrode is properly prepared (pointed if DC or rounded if AC) and protrudes 3-6mm
from the nozzle. If current remote control is available, adjust to low or minimum current. Start
procedure depend on the welding machines features: Scratch start, Lift arc or HF.
TIG welding can be carried out in all welding positions and the procedure is largely similar to the gas
welding forehand welding technique. Vertical welding is normally done upwards. Keep an arc length of
approximately 1-3mm. Note that a longer arc will increase the heat input and a shorter arc will reduce
it. If welding current remote control is used, the heat input may be adjusted through the whole process
by adjusting the current. Hold the torch at an angle of approximately 70° to the workpiece. The arc
may be used just to melt the edges of the joint together, or additional welding rod may be used.
Introduce the rod to the molten pool, but in such a way that it does not touch the electrode or enter the
arc between electrode tip and workpiece. The rod may be added continuously or in a slightly dipping
motion. The hot end of the rod shall be kept close to the melt pool and protected by the argon gas to
avoid oxidation, which will contaminate the weld. Hold the rod at an angle of approximately 20° to the
workpiece.
Finishing the bead by removing the welding rod from the pool. Adjust welding current to minimum and
extinguish the arc but keep the torch in place for 15 to 20 seconds with the gas flowing. This in order
to protect the molten pool and the electrode during the cooling-off period.
The tungsten electrode may be contaminated through contact with the molten pool or the welding rod.
It will also be contaminated (by oxidation) if the shielding gas supply is not opened before the arc is
struck, or if the gas is shut off before the electrode has cooled down to below red glowing temperature.
If there is little contamination the electrode may be cleaned by striking an arc against a copper plate
and letting it burn for a few seconds. Remember gas supply. If the electrode is heavily contaminated
the welding current supply must be disconnected, the electrode removed and the contaminated part
broken off. The electrode must be reground to the correct shape and replaced in the torch.
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