Basic Fundamentals of GTAW (Gas Tungsten Arc Welding)

Gas Tungsten Arc Welding (GTAW), also known as Tungsten Inert Gas (TIG) welding, is a precise and high-quality welding
process that uses a non-consumable tungsten electrode to create an arc and melt the base metal. It is widely used for
welding thin materials and applications requiring clean, high-quality welds.

1. Principle of Operation
1. Arc Formation: An electrical arc is created between the non-consumable tungsten electrode and the workpiece.
2. Shielding Gas: An inert gas (usually argon or helium) is used to protect the weld area from contamination by
atmospheric gases (oxygen, nitrogen, and hydrogen).
3. Filler Metal (Optional): Depending on the application, a separate filler rod may be added to the weld pool, unlike
processes like SMAW or GMAW, where the electrode itself acts as the filler metal.
4. Heat Control: GTAW allows for precise heat input, which helps in welding thin materials with minimal distortion.

2. Equipment Components
1. Power Source:
o Uses a constant current (CC) power supply, ensuring stable arc characteristics.

o Can operate on DC (direct current) or AC (alternating current) depending on the material.

2. Tungsten Electrode: A non-consumable tungsten rod that creates the arc.

3. Shielding Gas Supply: Inert gases like argon (Ar), helium (He), or a mixture are used to protect the weld pool.
4. Torch (GTAW Handpiece): Holds the tungsten electrode and directs the shielding gas.
5. Filler Rod (if required): A separate rod is added manually into the molten weld pool when necessary.
6. Foot Pedal (or Hand Control): Used for precise control over welding current, allowing for better heat management.
 Basic Fundamentals of GTAW (Gas Tungsten Arc Welding)

3. Tungsten Electrodes Types

Tungsten electrodes come in different types, each identified by color codes:
 Pure Tungsten (Green, WP) – Used for AC welding (mainly aluminum and magnesium).
 Thoriated (Red, WT-2%) – Used for DC welding (steel, stainless steel, titanium).
 Ceriated (Orange, WC-2%) – Good for low-current DC welding.
 Lanthanated (Gold/Blue, WL-2%) – Excellent arc stability for both AC and DC welding.

4. Process Steps
1. Setup
 Select the correct tungsten electrode type and size.
 Choose the appropriate shielding gas and gas flow rate.
 Set the correct welding current (AC or DC) based on the material.
2. Arc Initiation
 High-Frequency Start: Uses a high-frequency pulse to ignite the arc without touching the metal.
 Lift-Arc Start: Requires slight contact with the workpiece to initiate the arc.
3. Welding Execution
 Maintain a short arc length (about 1–3mm from the workpiece).
 Use a steady hand to avoid contamination.
 If needed, manually add filler rod into the molten pool while maintaining a controlled arc.
4. Post-Weld Cleaning
 After welding, allow the weld to cool slowly.
 Basic Fundamentals of GTAW (Gas Tungsten Arc Welding)

 If welding stainless steel or aluminum, clean the weld with a wire brush or pickling paste to remove oxidation.
 For titanium or reactive metals, ensure post-weld gas shielding until the metal cools.

5. Polarity Selection
 Direct Current Electrode Negative (DCEN or DC-): Common for stainless steel, mild steel, and titanium.
 Direct Current Electrode Positive (DCEP or DC+): Rarely used in GTAW due to excessive heat at the tungsten
electrode.
 Alternating Current (AC): Used for aluminum and magnesium to break the oxide layer and ensure a clean weld.

6. Advantages of GTAW
✔ High-Quality Welds – Produces clean, strong, and precise welds.
✔ No Slag or Spatter – Unlike SMAW or FCAW, there is no flux, reducing contamination.
✔ Versatile – Can weld a variety of metals, including aluminum, stainless steel, titanium, and copper.
✔ Controlled Heat Input – Ideal for welding thin materials and preventing warping.

7. Limitations of GTAW
❌ Slower Process – Compared to MIG (GMAW) or Stick (SMAW) welding, GTAW takes longer.
❌ Higher Skill Requirement – Requires steady hand coordination to control the torch and filler metal.
❌ Higher Equipment Cost – More expensive than SMAW or GMAW due to specialized equipment.
❌ Limited Outdoor Use – Shielding gas can be easily affected by wind.

8. Common Welding Defects & Causes

 Basic Fundamentals of GTAW (Gas Tungsten Arc Welding)

Defect Cause Solution

Shielding gas contamination, dirty Use clean metal, ensure proper gas
Porosity
metal flow

Tungsten Touching the tungsten to the weld

Keep a steady arc length
Inclusion pool

Reduce amperage, use pulse

Burn-Through Too much heat on thin metal
welding

Increase amperage, use correct

Lack of Fusion Insufficient heat input
technique

9. Applications of GTAW
 Aerospace Industry – Used for welding aluminum and titanium components.
 Automobile Industry – Ideal for precision welding of stainless steel and aluminum parts.
 Food & Beverage Equipment – Used for sanitary stainless steel welding.
 Pipe & Tube Welding – Critical for clean, high-purity welds in industries like pharmaceuticals and petrochemicals.

Conclusion
Gas Tungsten Arc Welding (GTAW/TIG) is one of the most precise and high-quality welding methods. It is ideal for applications
requiring clean, strong welds on thin or reactive metals. Although it requires more skill and control compared to other welding
processes, its benefits in producing high-quality, aesthetically pleasing welds make it essential in industries like aerospace,
automotive, and precision manufacturing.