4/28/25, 11:52 AM TIG Welding- Learn Components, Working, Advantages, Applications

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TIG Welding: Learn Definition, Construction, Working Principle,

and Applications
Last Updated on Jul 31, 2023

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TIG welding (Tungsten Inert Gas), also known as Gas Tungsten Arc Welding (GTAW), is a widely used
welding process known for its precision and versatility. Developed in the 1940s, TIG welding involves
the creation of an electric arc between a non-consumable tungsten electrode and the workpiece, while
an inert gas, such as argon, is used to shield the weld zone from atmospheric contamination. This
process allows for the fusion of various metals, producing high-quality, clean welds with excellent
control over the heat input.

This blog shall elucidate about Tungsten Inert gas welding, its Working principle, Construction,
Advantages and Disadvantages, and the various applications. This article will help you prepare for
exams like SSC JE ME and RRB JE Mechanical Engineering.

What is TIG Welding?

TIG welding uses an inert gas shielded arc welding process with a non-consumable electrode. The
electrode used in this process may consist of pure tungsten, tungsten with a 1 to 2% thoria mix, or
tungsten with 0.15 to 0.40% zirconia. Pure tungsten electrodes are less expensive but have lower
current-carrying capacity. Thoriated tungsten electrodes, on the other hand, can carry higher currents
and are preferred due to their ease of striking and maintaining a stable arc. Zirconia-added tungsten
electrodes offer better performance than pure tungsten but are inferior to thoriated tungsten
electrodes. Tungsten inert gas welding provides versatility and control for welding a wide range of
materials, making it a popular choice in industries such as automotive, aerospace, and construction.

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Working Principle of TIG Welding

Fig: Process of Tungsten Inert gas welding

Tungsten Inert Gas (TIG) welding operates on the same principle as arc welding, where a strong
arc is created between a tungsten electrode and the workpiece. Typically, the workpiece is
connected to the positive terminal while the electrode is connected to the negative terminal. This
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intense arc generates heat energy, which is utilised to fuse and join metal plates through fusion
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gas is employed during With
the TIG+welding
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clean weld surface.
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4/28/25, 11:52 AM TIG Welding- Learn Components, Working, Advantages, Applications

In the TIG welding process, the welding arc is initiated by striking it using a torch, facilitated by an
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electric spark generated by a high-frequency generator. This spark acts as a conductive path for
the welding current through the shielding gas, enabling the arc to be initiated while keeping the
electrode and workpiece separated. The inert gas creates a shielding atmosphere around the weld,
protecting it from external atmospheric influences.
Once the arc is established, the welder manipulates the torch in a circular motion, creating a
welding pool that varies in size based on the electrode size and current settings. Filler metal is
manually added to the leading edge of the weld pool as required. Gradually reducing the arc
current helps solidify the weld crater and prevents crack formation at the end of the weld. This
process allows for precise control and can be successfully executed.
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4/28/25, 11:52 AM TIG Welding- Learn Components, Working, Advantages, Applications

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Components Used in TIG Welding
The various components of inert Gas welding include

Power Source

The power source is the primary equipment unit in TIG welding, requiring a high-current power supply.
TIG welding utilises AC and DC power sources, with DC current commonly used for materials such as
stainless steel, mild steel, copper, titanium, and nickel alloys. Alternating current is suitable for
aluminium, aluminium alloys, and magnesium. The power source typically comprises a transformer,
rectifier, and electronic controls, with voltage requirements ranging from 10 to 35 V and current
ranging from 5 to 300 A to ensure proper arc generation.

Also, know the difference between AC and DC current.

TIG Torch

The TIG welding torch is a crucial component of the process, consisting of three main parts: the
tungsten electrode, collets, and nozzle. The torch can be either water-cooled or air-cooled, depending
on the application. The collet securely holds the tungsten electrode and comes in various diameters to
match the electrode size. The nozzle facilitates the flow of the arc and shielding gases into the welding
zone, featuring a small cross-section that promotes a highly intense arc. The nozzle requires periodic
replacement as it wears out due to the presence of intense sparks during welding operations.

Shielding Gas Supply System

In TIG welding, argon or other inert gases are typically utilised as shielding gas. The primary function of
the shielding gas is to protect the weld from oxidation by preventing the ingress of oxygen or other
atmospheric air into the welded zone. The choice of inert gas depends on the specific metal being
welded. A system is in place to regulate the flow of the shielding gas into the welding zone, ensuring
proper protection and control during the welding process.

Filler Material

When welding thin sheets in TIG welding, filler material is often not required. However, for thicker
welds, filler material in the form of rods is manually fed into the weld zone. These filler rods serve to
provide additional material and strengthen the weld as needed.

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TIG Welding Advantages and Disadvantages

Some important advantages and disadvantages of TIG Welding are discussed below.

Advantages of TIG Welding

Tungsten inert gas (TIG) welding offers several advantages:

High-quality and clean welds: TIG welding produces high-quality welds without the presence of
slag, resulting in stronger joints.
Corrosion resistance and improved strength: The inert gas shield automatically protects the weld
during the process, making it resistant to corrosion, more ductile, and stronger.
Versatility in welding positions: TIG welding can be applied in various positions, including
horizontal, vertical, or flat.
Manual and automatic application: TIG welding can be performed using both manual and
automatic techniques, providing flexibility in application.
Suitable for thin materials and wide metal thickness range: TIG welding is well-suited for thin
materials and can be applied across a wide range of metal thicknesses.
Minimal distortion: The small heat-affected zone in TIG welding results in less distortion of the
workpiece.
Controlled filler metal addition: Only the necessary amount of filler metal is added to the welding
puddle, reducing spatter and sparks.
Single shielding gas: TIG welding primarily utilises argon as the shielding gas for all applications.
Minimal finishing required: TIG welding often requires little or no finishing process, with
occasional grinding or preparation before painting.
Preferred for intricate works: TIG welding is the preferred choice for intricate projects where the
shape and precision of each weld joint are crucial.

Disadvantages of TIG Welding

TIG welding has some limitations and drawbacks:

Limited metal thickness: TIG welding is generally suitable for welding metal thicknesses up to
around 5 mm. Beyond this range, alternative welding methods may be more appropriate.
Skilled labour requirement: TIG welding demands high skill levels and expertise to ensure proper
technique, control, and weld quality. Adequate training and experience are essential for achieving
successful TIG welds.
Higher initial/setup cost: Compared to arc welding methods, TIG welding typically requires a
higher initial investment in equipment and setup. This can make it more expensive to implement,
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particularly for small-scale operations or occasional welding needs.
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Slower welding Study TIG welding
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is generally + More
slower compared to some other welding
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processes. The precision, control, and quality achieved in TIG welding often come at the expense
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4/28/25, 11:52 AM TIG Welding- Learn Components, Working, Advantages, Applications

of increased welding time.

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Application of TIG Welding

TIG welding finds primary applications in the following areas:

Aluminium and aluminium alloys: TIG welding is widely utilised for welding aluminium alloys,
stainless steel, carbon-based alloys, copper-based alloys, and nickel-based alloys, offering
excellent results and ensuring the integrity of the welds.
Welding dissimilar metals: TIG welding is particularly suitable for welding dissimilar metals,
allowing for the joining of different types of materials with precision and reliability.
Aerospace industries: TIG welding is extensively used in the aerospace industry due to its ability to
create high-quality, precise welds required for critical components and structures in aircraft and
spacecraft.

Also, get to know about Resistance Welding.

Differences between TIG Welding and MIG Welding

The following table lists the difference between TIG welding and MIG welding.

Tungsten Inert Gas Welding (TIG) Welding Metal Inert Welding (MIG) Welding

Uses a non-consumable tungsten electrode Uses a consumable wire electrode that is

continuously fed from a spool

Also requires a shielding gas (typically pure Requires a shielding gas (typically a mix of argon
argon or a mix of argon and helium) to and carbon dioxide) to protect the weld from
shield the weld zone atmospheric contamination

Generally provides slower welding speed Offers high welding speed, making it suitable for
compared to MIG welding large-scale production and thicker materials

Requires a higher skill level due to the need Can be easily automated, allowing for increased
for precise control over the heat and filler productivity and reduced operator skill
metal requirements

Preferred for welding thin materials and Commonly used for welding thicker materials, such
critical joints where precision and control as steel and aluminium
are paramount

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Offers excellent control, producing high- Provides good penetration and high deposition
quality
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Overview
Utilises aTest Series torch with a separate
handheld Uses a continuous wire feed system and a welding
filler metal gun

Versatile, allowing welding of various Suitable for both ferrous and non-ferrous metals
metals, including ferrous and non-ferrous
alloys

Requires cleaner surfaces and tighter joint Generally more forgiving of surface contaminants
fit-up and slight joint gaps

Provides superior control and weld quality Generally more cost-effective and faster for larger
for intricate or specialised applications welding projects

That culminates the discussion on Tungsten Inert gas Welding, its working principle, process,
Advantages and Disadvantages, including the various Applications. We recommend our readers that
they should appear in the SSC JE Mechanical mock tests and SSC JE ME Previous Years Papers. Also get
enrolled in the AE/JE Mechanical coaching to get a firm grip over the subject.

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