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Welding Welding equipment
TIG welding, short for “Tungsten Inert Gas Welding”, is a process known for creating precise, clean welds on various materials. It's especially useful for critical welding jobs in aerospace, food equipment, high-purity processing, and motorsports.
In this beginner's guide, we'll cover:
TIG welding uses a special torch with a tungsten electrode to heat the metal that is being welded. This process is protected by a shielding gas, typically argon, to keep out impurities, this is also fed from the torch. The power source generates an arc from the tungsten electrode to the workpiece which creates a molten metal pool. The reason that the electrode is made from tungsten is so that it does not get consumed, and filler metal is added into the molten pool separately. The key to good TIG welding is carefully manipulating the weld pool and consistently feeding the filler wire.
TIG welding offers several advantages, making it a preferred choice for many applications:
Selecting the right equipment is essential for your welding needs. Here are some things to consider:
Proper setup is crucial for successful TIG welding. Here is a streamlined checklist to follow:
Connect Torch:
Connect Remote Control:
Connect Earth Clamp:
Select Polarity:
Prepare Tungsten:
Assemble Torch:
Install Tungsten:
Insert the tungsten into the collet, ensuring the stick-out length affects arc performance.
Short Stick-Out Length (3 to 5 mm):
Medium Stick-Out Length (5 to 6 mm):
Longer Stick-Out Length (Greater than 6 mm):
Check and Connect Power:
Select Shielding Gas:
With the equipment set up correctly, you are ready to start welding.
Tungsten selection plays a critical role in achieving quality welds. Factors like material type, thickness, and the equipment being used influence the choice of tungsten. Different tungsten alloys are identified by colour bands painted on one end.
Here are some common tungsten types and their applications:
In the context of this article, it's important to highlight a crucial point regarding the selection of tungsten electrodes. Historically, thoriated tungsten electrodes were the go-to choice for TIG welding, and they are still commonly used in many regions. However, it is essential to note that thoriated tungsten contains 1-2% thorium which is radioactive, this has led to their prohibition in several European countries.
Here are some simple tips for beginners:
Incomplete Penetration:
Cause: Insufficient heat or welding too quickly.
Solution: Increase the welding amperage, slow down your travel speed, or both. Ensure proper joint preparation for better penetration.
Excessive Penetration:
Cause: Too much heat or slow travel speed.
Solution: Reduce the welding amperage or increase your travel speed. Adjust your technique to achieve a more controlled weld.
Tungsten Contamination:
Cause: Tungsten electrode touching the molten pool or filler metal.
Solution: Maintain a proper arc length and ensure the tungsten electrode is sharp.
Porosity:
Cause: Contaminants on the surface of the metal, inadequate shielding gas coverage, or improper gas flow.
Solution: Clean the metal thoroughly before welding, ensure proper gas coverage, and check for gas leaks. Adjust the gas flow rate according to the welding machine specifications.
Cracking:
Cause: Rapid cooling or excessive heat input.
Solution: Control heat input by adjusting the amperage and travel speed. Preheat the material if necessary and avoid sudden stops during welding.
Inconsistent Arc:
Cause: Unstable arc due to poor gas coverage, incorrect tungsten type, or improper settings.
Solution: Check gas flow and coverage, use the correct tungsten electrode, and ensure proper machine settings. Examine electrical connections for any loose or damaged components.
Irregular Bead Appearance:
Cause: Uneven travel speed, inconsistent torch angle, or improper technique.
Solution: Practice maintaining a consistent travel speed and torch angle. Experiment with different techniques on scrap material to find the most effective approach.
Undercutting:
Cause: Excessive heat leading to melting and removal of base metal.
Solution: Reduce amperage or increase travel speed. Ensure proper joint preparation and use a smaller electrode for better control.
Weld Spatter:
Cause: Contaminants on the metal surface or improper gas flow.
Solution: Clean the metal thoroughly and check gas flow. Adjust gas flow rate if necessary and ensure proper gas coverage.
Arc Starting Issues:
Cause: Contaminated or improperly prepared tungsten electrode, incorrect high-frequency settings, or poor electrical connections.
Solution: Ensure the tungsten electrode is clean and properly prepared. Check and adjust high-frequency settings. Inspect and secure all electrical connections.
Weld Discoloration:
Cause: Excessive heat or improper shielding gas.
Solution: Reduce amperage or increase travel speed to control heat input. Ensure proper shielding gas coverage and adjust gas flow if needed.
Always refer to the welding machine's manual for specific troubleshooting guidelines and recommended settings. Additionally, seek advice from experienced welders or instructors to address specific challenges.
In summary, mastering TIG welding can be a rewarding journey for beginners. By understanding the fundamentals, selecting the appropriate equipment, and adhering to best practices, it is possible achieve clean and precise welds across various applications. With dedication and practice,
TIG welding can become a valuable skill in any welding toolkit.For further insights into TIG welding, make sure to explore the following articles on ESAB University: