TIG or gas tungsten arc welding is one of the most common types of welding. Copper, aluminum, and stainless steel are easily machined by the TIG welding machine. However, when working with this technique, it is worth paying attention to some nuances, as well as learning more about what is TIG welding and how does it work? More on this later in our article!
TIG welding is loved by professional welders and is used in both large and small manufacturing plants (eg auto repair shops). The reason for this is its versatility. You can use this method both to form a high-quality weld, and for high-quality fusion of thick parts.
What is tig welding and how does it work?
If you haven’t encountered the term TIG welding or don’t know what it means, here’s a brief description. TIG stands for tungsten inert gas. The basic principle is that the arc and the welding gas are used together, with the arc going directly from the tungsten electrode itself to the surface to be welded.
Welding is performed using a non-consumable tungsten electrode. Because it generates a small but strong current from the tip to the surface, it provides a high-precision weld. The above are just some of the reasons why this method is popular for high-quality, precision projects.
When this method is chosen, inert gases (usual argon) are used to provide protection and cooling to the tungsten electrode and the weld pool.
At one point, helium gas was used to control the arc in the welding process. For this reason, TIG welding still sometimes continues to be called helium arc welding or tungsten arc welding GTAW.
Important: It is recommended that you consider the width of the metal so that the welding arc is adequate. For example, at low welding currents, the arc length is small.
What Do You Need to TIG Weld?
You need more than just a tig welder for TIG welding. Here is an overview of the equipment.
An Auto-Darkening Helmet
Before you start working with a TIG welder, it is important to protect yourself. A basic necessity for TIG welding is welding helmets, which provide reliable protection from sparks and burns. There are only 2 types of helmets: manual and automatic. It is recommended to use helmets with auto-darkening because their functions are considered the most advanced.
Gloves
It is recommended to choose gloves when working as a tig welder work. There are several types of these hand protection products on the market today. These include gloves made of genuine goatskin and cowhide or flame-retardant protective gloves. Most TIG welders use goatskin gloves because they are lighter and more flexible. It is important to carefully check the suitability of the gloves for your project before purchasing them.
Jacket
Welding jacket fabrics are recommended for thermal shock and electric shock protection just like welding gloves, and they come with a manufacturer’s warranty. Most craftsmen prefer cowhide jackets to goatskin jackets because they are more affordable. Flame-resistant fabric jackets would be an excellent choice because protective clothing with heat-resistant characteristics is required.
TIG Goggles
TIG goggles are necessary for protection against harmful radiation. These protective products are suitable for both large and small jobs where high temperatures are involved, you will need lenses with a blackout coating.
Welder
Different types and sizes of welding machines are known. It is recommended to choose “3 in 1” welding machines. They come in different sizes, from small to industrial, and can do a variety of complex weld metals.
Tungsten inert gas
In a TIG weld of aluminum, you need a special inert shielding gas (argon gas) as a shielding fluid to keep the weld pool intact. If you don’t want to buy a gas tank, you can always rent one.
Also, most TIG welders come with tungsten rods for the torch, but you will need to purchase more as you continue work.
Grinders, Sander, and Rods
A grinding wheel must be used to create a pointed tip out of tungsten. An alternative is a grinder, which is a machine designed for grinding. The filler wire must match the size of the metal being welded.
How Do TIG Welders Work?
If you are used to oxy-acetylene welding, then working with WD (weld metal) will not cause you any difficulties. During welding, it is necessary to use an electric torch with feeding the filler metal (rod) into the weld puddle of molten metal. This method also provides welders with a smooth start and stop, which makes this process, unlike other MIG welding processes.
The tig welder works as follows: a gas pedal is used to regulate the heating. It is possible to adjust the heat using the control panel of the oxy-acetylene torch.
TIG welding relies on a constant current power source – either DC or AC. But where did TIG welding start? It began right back in the 1930s and 1940s, as a way of effectively welding magnesium and aluminum. It was used extensively in the Second World War for effective and quick airplane repairs. TIG welding also grew in popularity quickly.
The foot controller provides smooth heating and then reduces the heat input when the welding process is complete.
We recommend first enrolling in local classes to learn the arc welding process in person from a professional. No one ever truly tig welding works. We are all just along for the ride. Ask any professional, and they’ll all say they are still learning. But, with some practice, you’ll make beautiful, consistent welds in a flat, horizontal position.
Selection of electrode diameter and tip angle and dependence on current
It is important to select the correct electrode diameter and tip angle for the level of welding current. As a rule, the lower the current the smaller the electrode diameter and tungsten tip angle.
In AC welding, as the electrode will be operating at a much higher temperature, tungsten with a zirconia addition is used to reduce electrode erosion.
Electrodes and equipment
The tungsten electrode is installed inside the torch – the tip is used to make contact with the metal to be welded. To operate the machine, press the foot pedal, then gas will flow and an electric current will flow, causing an electric arc.
By releasing the foot pedal, you can stop the process. TIG welds are created by layering individual small welds directly on top of each other.
A ceramic cup covers the tungsten electrode, directing the flow of gas. These cups are available in several sizes for a variety of welding applications.
Various tools for gas tungsten arc welding
A variety of welding equipment is available that includes a wide range of guns, reducers, and torches.
And each piece of equipment serves a different purpose. By way of example, a MIG welder can need different equipment than plasma cutting processes.
What’s the Difference Between MIG and TIG Welding?
To understand TIG welding, a distinction must be made between the processes that occur in MIG welding. In the MIG welding process, the metal wire is introduced continuously into the weld. So that two metal objects can be easily joined, wire is used as filler metal. TIG welding, on the other hand, provides a connection between two metal objects using inert tungsten gas, and filler metal may or may not be used during work.
The MIG welding technique uses filler material to join different objects. This feature simplifies welding when working with metal items of large size and thickness. Consumables are not always used in TIG welding due to the heat generated. The TIG torch must be heated to a high temperature to weld thin metals quickly.
When to Use TIG and MIG Welding
How thick should the metal be?
The thicker metals, the harder it will be to join with just a single heating session. Therefore, if the material is thick, it is best to use a MIG-type weld. A TIG electric torch is not sufficient for this process.
What conductivity value is required?
Consideration should be given to whether the metal you are welding has a high level of ductility. A high level of the latter will require longer heating of the metal, which will result in increased energy consumption.
When working with electrically stable metals that heat up faster, welding can be done without filler material, which makes TIG welding the most suitable method.
Does the metal have to be smooth?
If you use filler material during welding, it will result in a lot of welds spatter. During the welding process, an additional task would be to remove the spatter. That is why the TIG welding technique is considered the best in such a case.
Are dissimilar metals welded?
The TIG method is not recommended for welding dissimilar metals because of the weak bonds that form between the welds. Nevertheless, there are circumstances where different metals need to be welded. In this case, stick welding or MIG welding will suit you, because in this case, filler wire is used and the result is a high-strength connection of the final product.
What is the TIG welding used for?
Gas tungsten arc welding is usually used to obtain accurate welds and butt joints of various metals, such as stainless steel, aluminum, nickel alloys, chrome materials, and so on. It is also used for welding simple mild steel if the absolute joint quality is required.
The process of welding thin and fine metals
TIG welding metals such as aluminum is the best way because it allows the welder to achieve greater precision.
The TIG welder’s job can also do a variety of things, such as apply decorative elements to metals. TIG gives you more control over this weld joint, allowing you to achieve precision.
Variety of DIY projects
Easy and convenient TIG welding can be used by beginners and experienced welders alike when working on DIY projects. As an example of such projects, consider assembling furniture, bicycles, carts, and shelving.
TIG welding project execution methodology
Welders can work on a variety of metal products such as titanium, aluminum products, and copper using TIG welding. This method is also necessary for complex jobs, such as making bends or curves on any metal object. Listed below are the steps required to complete a TIG welding project.
1. Electrode selection
To choose an electrode, it is necessary to be guided by the type of metals that are being welded. For example, if aluminum is being welded, a pure tungsten rod is recommended.
2. Select a rod to work with
The rod is prepared by grinding to the desired degree of use. In most cases you will need to grind the rod, especially if it is brand new, rounded at the tip, or not sharpened. By grinding, you will decrease the amount of energy used during welding.
3. Inserting the electrode tip into the collet
To do this, loosen the electrode holder, insert the electrode and secure it with the screw. You don’t have to do this step if the electrode is already in place.
Inside the copper collet, there are many holes through which the Prepare metal inert gas that surrounds the tungsten during the welding process flows.
4. Defining settings for TIG welding
Three settings are available for welders using a TIG welder: AC, DCEP, and DCEN. The AC setting is best used when welding metals such as aluminum. For tip or stick welding, the DC electrode setting (DCEP) is preferred. For welding steel metals, the DC negative electrode setting (DCEN) is preferred.
Use the following setting, “Clear/penetrating”, to set to the sharp end. If using a scale of 1 to 10, set it to 7. Turn “Air on” mode on for about five seconds and set “Max Amps” to about 250.
5. Prepare a metal inert gas
It is necessary to use pure argon when welding aluminum metals or argon mixed when welding steel.
6. Organization of the workplace: welding table for work
The provision of a workplace is a prerequisite for correct and safe welding. The process must be carried out in compliance with health regulations.
It is convenient to place the product on a table to facilitate the welding process. This increases the welding speed and facilitates hard-to-reach areas.
It is a good idea to place the device on the table:
- Holding the fixture when repositioning the workpiece;
- Quick access to the wear parts and easy change of electrodes;
- Positioning of the tools (hammer, saw, welding torch, slag remover, wire brush);
- Ignition of the electrode on rough surfaces;
Installation of non-standard structures with protrusions in special holes.
7. Preparing for work
Protective equipment is required to ensure safety and protection from radiation, high temperature, various burns, and harmful gases emitted during welding operations. Welders must wear thick gloves, a welding helmet, closed-toe shoes, and a special gown.
8. Carry out the final check
The final step is to make sure that all necessary equipment is in place and working at optimum efficiency. You should also check that your equipment is properly worn and selected according to the welder’s instructions.
Transfer the electrode to the hand you use most often and test it. During the test, make sure that the electrode moves freely and is easy to work with before you start.
Gas tungsten welding arc for Beginners
To understand TIG welding aluminum for beginners, there are some basic tips to learn. First and foremost, to learn TIG welding, it is recommended that you enroll in courses at educational institutions to learn in person from a professional. In reality, almost no one can master TIG welding to perfection. Just ask any professional, and they will all answer that they keep learning. However, with a little practice, you will be able to make even and horizontal welds.
1. Operate at minimum power
Higher power can cause the weld to burn through, which necessitates the use of minimum power levels. Using the minimum amount of power makes it possible to develop a “puddle” technique that is suitable for forming strong and consistent welds.
2. The angle of inclination of the torch
During welding, the torch should be directed at an angle of at least fifteen to twenty degrees from the plane of the material and the direction of the flow of electric current. This angle allows easy access to the filler material and improves the visibility of the welded part.
3. Maintain cleanliness of welding materials
Make sure the welding metals are clean. Always have a wire brush to clean dust and other contaminants from the metals.
4. Try not to let the filler rod melt directly
Remember the principle: the torch melts the base metal and the puddle of molten metal causes the filler rod to melt. The precise welds are difficult to obtain since direct melting will make it difficult to melt the filler rod because it will result in a weak joint.
5. Wear protective equipment
Because tungsten electrodes emit low levels of radiation, wear helmets with blackout lenses. You will also need to use a protective respirator to protect against toxic gas flow and fumes. Ensure that you weld in a well-ventilated area to reduce the risk of dust that degrades the quality of the welds.
6. Use the appropriate type of tungsten
Different types of tungsten are used for different machining types of metals. Red tungsten is suitable for machining steel metals, and green tungsten is suitable to weld aluminum and other metals.
FAQ
What shielding gas is used in TIG welding?
Two types of gas are used for TIG welding, Helium, and Argon. However, in most cases, it is inert gas like Argon is used rather than shielding gas. Helium has a high cost. Inert gas in TIG welding is needed to close the weld pool from oxygen, which can harm the future connection. Argon is a harmless inert gas. It is not harmful to the welder when inhaled and, just as importantly, Argon is not explosive.
Why is it called TIG welding?
The name comes from three words: «tungsten inert gas». It is a process that uses an electric arc – it is formed between the workpiece and the electrode to further melt the material. TIG welder work: when performing TIG welding, a filler rod is used. An electric welding torch should be used during the tig welding process, feeding the filler rod into the molten puddle.
What metals can I weld with TIG?
You can weld more metals than any other method. You can weld corrosion-resistant steel, aluminum, magnesium, copper, bronze, etc.
What are the advantages of TIG welding?
Plus, you can TIG weld in any position; vertically, flat, or even overhead. Since TIG weld entirely depends on melting the metal using an electric current, it works best for a thin or narrow metal piece. Can I perform TIG welding outdoors? In this case, you can, provided the joint is protected from the wind.
Conclusion
It is recommended that you take the time to learn tig welding. Once you get an understanding of this type of tig welding process welding you can start working on your first project.
