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Differences Between TIG Welding and Brazing/Soldering 

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Differences Between TIG Welding and Brazing/Soldering 

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Summary: Brazing is a process that only melts the filler metal to bond two parts together. Welding melds two base metals to each other by melting the base metal and filler metal together. The main mechanical difference lies in the temperature used for each process. Brazing and soldering are both much colder processes than welding, due to the fact that they don't melt the base metals together. Brazing would be used for parts that don't need to hold structural weight or pressure, it's mostly used for delicate jewelry or electrical components.

Reflection: Brazing and welding are two very different processes that are used for two very different applications. The article clearly shows that welding is used for structural and pressure vessels while brazing is usually used for less important aesthetic parts. It also goes into detail about the idea of melding dissimilar metals together, which brazing is incredibly good at doing since it doesn't actually melt the base metals, just the filler rod. This is good for many different applications but not anything that needs to hold weight.

Citation: Bryant, Liam. “Brazing vs Welding: Key Differences Explained.” Beginner Welding Guide, BeginnerWeldingGuide.com, 6 Apr. 2023, https://beginnerweldingguide.com/brazing-vs-welding/#:~:text=In%20brazing%2C%20only%20the%20filler%20metal%20is%20melted%2C,welding%20is%20better%20for%20parts%20that%20require%20durability.

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Brazing joins metals using a filler metal above 840°F (450°C) without melting the base metals, while welding fuses base metals by melting them. Welding typically provides stronger joints, whereas brazing is suited for delicate or dissimilar materials and complex assemblies, with lower heat and distortion risks.
So, in which situation is one or the other better? And what equipment do we need to use these two different techniques? Fortunately for you, you won't have to do all the thinking, as in this article, I'll share all that you need to learn about brazing vs. welding.

What Is Brazing?

In brazing, you only melt the filler metal instead of also melting the base metal. The liquified filler is applied in a joint between the pieces, forming a bond. It accomplishes this by a principle known as ' capillary action.'

There are a few methods of brazing, including:

The filler metal is heated above its melting point in a brazing operation. It's protected by flux materials to prevent it from reacting with the atmosphere. Without it, the joint that's produced may have unwanted impurities.

The filler's always a metal that melts at a temperature over 842°F, but it's never above that of the base materials.

The base materials are preheated for the filler to fuse. However, it's never heated anywhere near the melting point.

The liquified filler is then applied between the base materials, fusing the pieces. Once it cools down and solidifies, it forms a joint.

Brazing is most commonly used to weld:

What Is Welding?

Welding works by melting the base materials and then joining them. It may or may not involve shielding gasses or filler metals.

There are different kinds of welding processes, which include:

Out of these methods, arc welding is the most commonly used.

In a welding operation, a portion of the base material is heated above the melting point. The methods used in welding can melt even metals with the highest melting points.

The resulting points of molten metal are then joined with a filler material. These need to be protected from the atmosphere to prevent any impurities. For that, we can either use flux material or shielding gas.

Brazing vs Welding

These two different metal-fusion processes have different advantages and disadvantages. It all boils down to your preferences and purposes.

Advantages of Brazing

Joints made using brazing come with very little stressing and thermal distortion compared to welding.

Brazing uses far less energy than wielding, as it requires less heat to operate. As such, it's far cheaper to use.

Because it only melts the filler metals, brazing can join two different base materials.

Brazing doesn't require heat treatment after processing.

As the base materials are never melted, they can keep most of their physical properties.

It's easier to learn to braze than to weld. The latter requires precision in the application of heat and deposition of the filler; the former relies on the principle of capillary action.

Suitable for extremely thin metals, as extreme temperatures could damage these.

Advantages of Welding:

A joint made by welding is typically stronger than the base materials it was made from. Welding is the better process of making strong, permanent joints.

Due to the intensity of heat used in welding, it's more localized. This makes it practical to join metal pieces at one point instead of a broad area.

Welding is well suited to joining larger pieces of metal.

Disadvantages of Brazing:

Brazing forms joints with less strength than those produced by welding.

Brazen joints can't be used in higher-temperature environments, unlike welds.

Disadvantages of Welding:

Welds may require a post-processing heat treatment to fix stresses in the joint.

Usually, welding can only fuse similar base materials.

The intensity of heat in welding can result in distortion, warping, and cracking of your weld.

Equipment Required

As brazing and welding are different processes, the equipment they need is sometimes different.

Brazing Equipment

1. Filler material and flux solution. The most commonly used filler metals are fluorides, alkalis, chlorides, and fluoroborates.

2. Either furnace, induction, chemical bath heater, or torch for heating the filler.

3. Protective gear, including safety glasses, hearing protection, welding boots, auto-darkening welding helmet, welding gloves, and a fire-resistant coat.

4. A secure electrical supply.

Welding Equipment

1. Welding torch

2. Electricity source

3. Filler material

4. Shielding gas, such as helium, argon, or a mixture of both.

5. Fuel cylinder

6. Oxygen cylinder

7. Protective gear

When to Use Each?

Brazing is ideal for manufacturing parts with different metals and complex designs. It's also suitable for mass production as it's easier and uses less heat.

On the other hand, welding excels on larger components that require more durability, such as vehicle frames.

In Conclusion

In brazing, only the filler metal is melted, while welding melts both base and filler materials. It also requires less heat than welding.

Finally, brazing is suitable for mass production and complex designs, while welding is better for parts that require durability.

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Brazing vs Welding: Key Differences Explained - Beginner Welding Guide

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Brazing joins metals using a filler metal above 840°F (450°C) without melting the base metals, while welding fuses base metals by melting them. Welding typically provides stronger joints, whereas brazing is suited for delicate or dissimilar materials and complex assemblies, with lower heat and distortion risks.

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Summary: TIG welding stands for Tungsten Inert Gas welding. It uses an inert shielding gas and a non-consumable tungsten electrode to produce a very clean and hot arc without causing any imperfections to be produced in the weld pool. TIG is incredibly useful for welding many types of metals, much more than any other process. In the case of exotic metals, TIG welding is by far the cheapest and most accessible method of welding and is still chosen by many high-quality welders over modern processes like laser welding. TIG welding is used when a incredibly clean and delicate process is required. Projects like welding thin or rare metal usually call for the use of TIG welding.

Summary: This article gives a good overview of the TIG welding process as well as many of it's uses. One thing that stood out from the others is it's use on rare metals. TIG welding is incredibly clean and thus is easy to use on exotic metals that normally would require an entirely different flux or cleaning process otherwise. With TIG welding the only difference is a change in the filler rod material and/or a change in the polarity. This article shows the usefulness of TIG welding in this, and many other ways.

Citation: Berk, Alexander. “What Tig Welding Is Used for (& How to Know When to Use It) .” Welding Mastermind, WeldingMastermind.com, 5 Sept. 2022, https://weldingmastermind.com/what-tig-welding-is-used-for-how-to-know-when-to-use-it/.

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"This post contains affiliate links, and I will be compensated if you make a purchase after clicking on my links."

So, has learning how to weld caught your interest lately? If so, you're probably wondering what the difference is between TIG welding and MIG welding, and when you should use TIG welding. TIG welding offers you the opportunity to finish projects with thinner metals as you weld. Most welders use TIG welding when melding very thin metals that MIG welding can't handle, or to touch up and finalize projects.

What is TIG welding used for, and how do can one know when to use it? TIG welding stands for tungsten inert gas welding because a tungsten electrode runs the current through the metals being joined as you weld. You typically use TIG welding to complete welds when metal objects are very thin, and it allows you to touch-up your welding projects.

Since there isn't a lot of information on the Internet today covering TIG welding and when you should use it, we created this article to help you out. Below we'll include what TIG welding is used for, how MIG and TIG welding work, and when you should use TIG welding. We'll also finish by discussing how to weld with a TIG welder.

What is TIG Welding?

Before we get too heavily into how you'll be using TIG welding, we first need to define what TIG welding is, and when you'll use it. So, we'll start with the definition of TIG welding and give you a brief overview of what TIG welding will do for you.

TIG is short for inert tungsten gas, and TIG welding refers to gas tungsten arc welding or GTAW. TIG welding starts with a non-consumable tungsten electrode charge that consistently provides current so that a person can weld with their welding arc.

As the TIG welding is completed, the tungsten and weld puddle are both cooled off with an inert gas, which is usually argon, providing you with safety and protection. In many ways, TIG welding resembles oxy-acetylene welding because you're using filler material so that you can reinforce your welding creation.

How Do TIG Welders Work?

If you've ever done welding with an oxy-acetylene torch, then you already know most of the steps involved with TIG welding. With TIG welding, you'll be using an electric torch with a welder hand that will be feeding filler rod into the molten puddle as you weld.

With TIG welding, you get the capability to soft start and soft stop, which is the significant action that distinguishes TIG welding from other kinds of electric welding. Many experienced welders enjoy using an accelerator pedal to keep the heat under control if they like working at a bench. Other skilled welders prefer using the fingertip remotes on the torch when welding because the remote gives welders the ability to modify their heat while they are in the process of welding.

Parts of a TIG Welder

Before you jump into your first TIG welding project, you'll need to know how to use the TIG welder. So, we'll familiarize you with the parts of a TIG welder and the functions of each specific piece to get you started on the right foot immediately below.

The Work Lead

The first important part of a TIG welder is the work lead, which is also known as a ground cable that features a clamp. Before you start welding, you'll need to attach the workpiece so that it is combined to the metal surface you are planning to work on as you prepare to begin. If you're not sure how to identify the welding lead, you can find it by knowing it has the electric TIG torch at the end of it.

You'll also found a cable connected to the work lead, which carries the argon gas (or another coolant type inert gas on the TIG welder if the TIG welder doesn't use argon). The inert gas helps to coat the electrode and protects the weld from being contaminated by the outside air. So, you'll need to make sure you are also using a gas bottle and a regulator. However, you don't want to use the same gas that you use in your MIG welder.

The Small Tungsten Rod

We can break down the TIG torch in a little more detail because there are several parts involved on the inside of the TIG torch. The small tungsten rod (which can come in many different sizes) on the inside of the torch works as the electrode. This electrode is designed to not burn up like a filler rod would under the same circumstances. You can also sharpen the tungsten as you see fit, making it a point or a ball so that you can match it to what you are welding.

The Copper Collet

On the tungsten, a copper collet can be found holding it together. That copper collet will help you adjust the length on the tungsten since the tungsten sticks out of the welder's cup. The ceramic cup, which is usually pink on most TIG welders, can be unscrewed, removed, and replaced whenever you need to modify it. There are many different sizes of cup outlet diameters on the market, and you need to match that to what you'll be welding.

The body of the collet features many cross-holes that permit the gas to move into the cup and then circle the tungsten. Oxygen is left out of the mix because of oxygen contaminates welding projects. If you want to reduce the collet's hold on the tungsten, you can loosen the back cap on the collet. If you want to remove the tungsten to sharpen it or replace it for any reason, you'll need to loosen the back cap on the collet.

Foot-Operated Mechanisms

Also, many TIG machines utilize foot-operated mechanisms that provide for varying amperage control. Typically, the maximum amperage you'll want will be already pre-set on your welder. During the process, you might want to change up the amperage, and you'll be able to do that with this mechanism.

Many welders find they need this part when they are welding alloy steels because the foot control lets them slowly bring up the heat, and then gradually reduce the heat once they are done. By doing a soft start and soft stop like this, the temperature won't shock the metal. It's crucial to avoid shocking the metal because if you do, you'll wind up with a brittle weld.

Controls

You'll also find numerous controls on your TIG machine. Probably the essential command you'll need to know on the TIG machine when you are welding is balancing, which is very important when you are welding aluminum. The balance helps you keep the cleaning versus the penetration of the aluminum to a minimal amount. The more you up the balance on the machine, the deeper your weld will penetrate the metal.

Other controls you'll find on your TIG machine include a choice between a normal or a pulsed mode. If you use the pulsed mode when welding aluminum, you'll discover that the amperage on the TIG welder varies itself automatically. That helps you keep down the heat on your workpiece so that your weld comes out better. Most welders use pulsing to create a "stacked dimes" appearance or to create a wave-like pattern in their weld.

Now that we've covered the essential parts you'll need to know on a TIG welder, we'll discuss how MIG and TIG welding work and when you'll use TIG welding versus MIG welding below.

When is TIG Welding Commonly Used?

TIG welding is commonly used in the following scenarios:

TIG welding works best on small, thin metals, especially aluminum. Since TIG welding provides the welder with more accuracy, it's easier to perform actions on thin metals as a result.

Whenever you need a precise, pretty weld, you'll want to consider opting for TIG welding since TIG welding gives you more control, allowing you more precision.

When you need a nice weld bead appearance for your project, you should use TIG welding. Since TIG welding allows for more control and precision, you'll get a better appearance with your weld when you use TIG welding. There are some jobs out there that require TIG welding for a good bond and a more stylish appearance. For example, piping, high-profile consumer goods, and nuclear work often require TIG welded bonds.

If you are welding materials that are very thin, or if you are welding materials that are in the five-thousandths inch range, you won't be able to use other types of welding. The only type of welding that will work when looking at thin, small areas is TIG welding because of the greater amount of accuracy you'll get.

TIG welding can also be used for a variety of DIY projects like making a bicycle, tools, carts, furniture, shelving, and can even be used in jewelry repair.

MIG welding and plasma arc welding have replaced TIG welding in many industries like aerospace, automotive, and manufacturing.

MIG and TIG Welding

For you to understand more about TIG welding, and when you'll be using TIG welding, we need to break down both MIG welding and TIG welding. We'll cover when you'll be using MIG welding, and when you'll be using TIG welding so that you can successfully create your first welding project.

So, we'll start by breaking down MIG welding in a bit more detail. MIG (metal inert gas) welding uses a constant feed through a metal wire into the weld you are creating. The cord uses the supply it's getting like it's filler material so that you can combine two metal objects easily. Some also call MIG welding GMAW or Gas Metal Arc Welding. By contrast, TIG welding uses inert tungsten gas to join the two metal objects together, and may or might not use a filler as you weld.

MIG welding uses a consumable filler while you weld to combine metal objects. That means MIG welding is easier to use when you are trying to weld together larger, thicker metal objects. Typically, if you are working with more abundant metals, a MIG weld can melt together those denser objects in far less time than a TIG weld could weld them together.

Since TIG welding doesn't always use a filler material, the TIG torch needs to be able to get hot enough to meld the two objects together. You can see why it would be easier to do that with thinner pieces of metal compared to thicker ones. If you use TIG welding with more abundant metals, you might wind up cracking your metal and experiencing other issues, like a brittle weld.

So, when you start welding, you'll need to know that you'll use MIG welding for very thick, heavy-duty pieces of metal. However, when you are welding thinner pieces of metal, you'll want to use TIG welding instead.

To give you a little more insight about when you'll be using TIG welding and when you'll use MIG welding, we'll discuss the type of control you'll have with both types of welding so that you'll better understand when you should use TIG welding.

Control in MIG and TIG Welding

When doing TIG welding, you need to have a lot of control over things like timing, electric current, and pressure as you are welding. That's why many newbie welders like starting with an automated, computer numerically-controlled (CNC) welding machine. These machines give welders a lot of control over their welds when doing TIG welds. Also, these machines are very reliable and much easier to use than a manual welder.

So, is one of these types of welding options better than the other? When trying to answer this question, it depends on what you are trying to weld. Like we mentioned earlier, you'll want to use MIG welding when completing heavy-duty welding work with larger, thicker pieces of metal because of the filler you'll get when using the MIG welder. On the other hand, when you are joining smaller pieces of metal together, like wires, you'll want to use TIG welding. TIG welding directly joins two pieces of metal, meaning you don't need to use a filler when TIG welding.

That saves you money in the long-run when you are completing your welding projects. TIG welding also typically requires a lot less maintenance than MIG welding because the welding electrode in TIG welding isn't continuously consumed while you are welding. Still, when TIG welding, the welding electrode has to be cleaned and polished correctly between uses. You'll need to especially make sure you are cleaning your TIG electrode whenever you weld stainless steel.

So, you'll be using TIG welding when you are melding smaller pieces of metal together, and MIG welding when melding thicker pieces of metal together. There is no one-size-fits-all solution when it comes to welding. You'll have to decide what type of welding process to use on a case-by-case basis to produce the best results.

To help you how to analyze that case-by-case basis a bit better, we'll cover below when you should use MIG welding, and when you should use TIG welding in a bit more depth.

When to Use TIG and MIG Welding

So, you probably want more specifications about when you'll be using TIG welding, and when you'll be using MIG welding. We'll cover what type of welding you'll want to use for which kind of project in a bit more detail below. To figure out which welding technique you'll want to use, you'll need to ask yourself a few questions and consider the answers.

What's the Thickness of the Metal?

Metal thickness is something you'll need to consider because the thicker the metal, the harder it is to join with just heat alone. So, with very thick pieces of metal, your TIG welding torch probably won't be enough. So, when metal is very dense, you should skip TIG welding and use MIG welding instead.

What Electrical Conductivity Do You Need?

You'll also need to take a look at how malleable the metal is that you are joining together. If you are working with highly ductile metal, you'll need to heat the metal for a more extended period, and that uses up more energy. However, a metal that is electrically-resistant typically gets hotter faster, so you can weld it without filler material and use your TIG welder for that.

Are You Welding Dissimilar Metals?

We don't recommend that you weld dissimilar metals since a lot of weak bond problems could result, but sometimes we understand that you might need to do it anyway. If you are welding together two dissimilar metals, then you're going to want something that uses a filler and bonds. So, you'd use MIG welding for this.

Does the Metal Need to Be Smooth?

You'll also need to factor in how smooth you want your result to be. Using filler materials means you'll have more weld splatter and more work when you want something smooth. That's where doing direct metal-to-metal welding comes into play, and you'll want your TIG welder for that.

Now that you have a better understanding of when you'll be using TIG welding, we'll cover the process of how to complete a TIG welding project.

How to Complete a TIG Welding Project

Since we've covered enough up to this point to give you a good idea of when you'll need to use TIG welding, we'll now cover how to complete a TIG welding project. You can use TIG welding for a variety of metals like copper, titanium, and aluminum. Also, TIG welding is excellent when you are completing tricky projects, like curves or rounding off any metal object.

Below we'll outline the steps to help you complete your next TIG welding project.

Step #1: Select Your Electrode

First, you'll need to select the electrode you'll be using. More than likely, you probably have the right electrode on your TIG already. If you're welding aluminum, it's best to use a pure tungsten rod. Throughout this example, we'll be using the specific alloy 6061 aluminum as a point of reference.

Step #2: Get the Electrode Ready

Next, you'll want to grind the tungsten rod to an excellent point so that you're getting your electrode ready. You'll need to complete this step if the rod is brand-new or it isn't pointed or rounded on the tip. As you weld, the tip rounds out because of the heat. We suggest using a ballad tip for AC welding, and when DC welding, use a pointed tip.

Step #3: Place the Electrode in the Collet

Next, you'll need to unscrew the electrode holder, put your rod in, and then screw the back in again. You can skip this step if you already have your electrode ready.

Step #4: Select Your Settings

With a TIG welder, you'll have three options in settings-DCEP, AC, and DCEN. When welding aluminum, you'll use AC, so that's the setting we selected for our aluminum project. However, for future reference, we'll also describe the other parameters. DCEP refers to "DC, Electrode Positive," which you'll use when balling your tip or stick welding. The setting, DCEN, stands for "DC, Electrode Negative," and is the setting we use when welding steel.

Next, you'll need to set the "Cleaning/Penetrating" setting, so it's more on the penetrating end. We suggest around seven if working on a scale from 1 to 10. Next, put the "Air on" setting to around five seconds if you can. After that, set the "Max Amps" setting so that it's high. We suggest putting the "Max Amps" setting at around 250.

If you need other information about specific settings, you can use this handy settings calculator.

Step #5: Get Your Gas Ready

Since our example is using aluminum, we'd use pure argon as our gas. If you are welding steel, you'll use a mix of argon and carbon dioxide.

Step #6: Get Your Metal and Welding Table Ready

You'll need access to a large metallic area so that you can allow electricity to flow through the metal you are welding. We typically use a welding table that's made just for this reason. However, if you don't have the funds to purchase a welding table right now, a large, flat sheet of metal will work just fine.

We recommend using a wire brush to scrub off the surfaces of the metal and keep that brush separate from what you use to clean steel. Keeping the surface of the metal clean means, you'll wind up with prettier welds. It's also a good idea to wipe the welding rods down with acetone.

Remember, you'll need to clamp your metals so you can keep them in place as you are welding. We also recommend spraying down your welding table with anti-spatter. That way, when metal leaks off, it won't stick when it lands.

Step #7: Get Geared Up

To keep your TIG welding days as safe as possible, you're going to need the appropriate gear. So, after you've got your TIG welder ready to go, you'll need to get yourself prepared to go to make sure you stay protected. You'll need some thick leather welding gloves, a welding helmet, and closed-toe shoes. Also, since you can get sunburned from TIG welding, you need to wear a welding coat. You also might want to get a good, bright flashlight so you can see what you are doing while you weld.

Step #8: Do a Final Check

Now you'll need to do a final check and get ready to weld. Place the electrode in your dominant hand and test it out. Ensure that the electrode moves freely and is easy to work with before you start.

Step #9: Let's Get Ready to Weld!

Now you're ready to start welding with your TIG welder! Start with the electrode about one-inch away from the metal with which you are working. You don't ever want to touch the metal with the electrode. If that happens, you'll wind up with molten aluminum on the electrode. If you do wind up accidentally touching the metal and you get aluminum on the electrode, you'll need to stop, turn off your welder, take off the tungsten rod, and grind it down again.

Next, press down on the foot pedal so that you wind up with a rush of current and heat into your metal. You want to heat the metal quickly and start up your weld pool. To get the pool to start forming, you'll need to start on an edge. After the pool forms, you need to touch the rod in and make sure you don't heat the metal for too long. If you cook the metal for too long, it will warp.

After the pool forms, ease off the pedal and start aiming to control the heat that the metal is getting. Remember, as you are doing this that welds shrink as they cool, so you want to alternate sides so that your welds remain even. Also, by rotating sides, you'll be preventing the metal from warping. If you don't change sides, you might wind up warping the metal.

Step #10: Draw a Bead

Once you are done tacking, you'll remove the clamps from your metal. Then, you'll start your weld pool. After your weld pool is going, you'll want to lighten up on the pedal, just like we described above. Now you are ready to draw a bead, but you'll need to keep an eye on a few things.

If the metal burns too fast or starts melting too quickly, then you've got too much current going into the metal. If that's the case, ease off the foot pedal. On the other hand, if you notice the metal getting flaky but not liquid-like, then you'll need to push the pedal down harder.

Since our example is aluminum, we'll start with welding aluminum. When using aluminum, move the electrode in the direction of the rod while you are feeding the rod into the pool of metal. You'll want to keep the rod to the electrode's side, a process known as "leading" the electrode.

When working with steel, you want the electrode to travel down the weld line first, with the rod chasing, or "following" the heat.

Final Thoughts

Now that we've covered what TIG welding is, how it is used, and the steps to getting started with TIG welding, you should be all set to begin your welding project. Knowing how and when to use TIG welding means you should be able to create beautiful pieces once you are finished, and enjoy your new hobby for hours on end.

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What TIG Welding is Used For (& How to Know When to Use It) ﻿ - Welding Mastermind

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"This post contains affiliate links, and I will be compensated if you make a purchase after clicking on my links." So, has learning how to weld caught your interest lately? If so, you're probably wondering what the difference is between TIG welding and MIG welding, and when you should use TIG welding.

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Summary: TIG welding is used for various things. Not the least of which is welding all different types of metals that are not able to be welded easily through the stick or MIG welding processes. TIG is used for welding dissimilar metals to each other, welding metal that is too thin for other processes, or welding metal that is just too finicky to be welded with a more aggressive method. TIG is very clean and precise which is good for almost all different types of metals. In the case of rare earth metals, TIG can be used for many different alloys that would end up a molten mess with most other processes.

Reflection: TIG is a good process for any kind of metal that isn't the basic aluminum or steel. The article demonstrates this through an excellent explanation of the process of TIG welding and the properties that make it good for different types of metal. It is very clean, easy to manipulate, and only requires a change in filler rod and possibly polarity to be able to weld even dissimilar metals together.

Citation: Dekker, Cameron. “What Is TIG Welding Used for? (& How to Know When to Use It).” WaterWelders, WaterWelders.com, 31 Jan. 2023, https://waterwelders.com/what-is-tig-welding-used-for/.

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Last Updated on

Have you ever had an interest in welding? You probably have trouble differentiating TIG from MIG welding and when to use either of the two methods. For many years, welders have been using TIG welding to finish projects with thinner metals that MIG could not handle.

So, what's TIG welding used for, and how do you know when to use it? TIG is an acronym for tungsten inert gas. The name basically describes the welding process since a tungsten electrode runs the current through the metals being welded. Welders typically use TIG welding to complete welds when metal objects are very thin and provide a touch-up for their projects.

What is TIG Welding?

TIG welding is a process that uses non-consumable tungsten. In this method, heating is done by placing an arc between a tungsten electrode and the workpiece. Welders use this procedure with shielding gas and may or may not use filler metals. Some of the primary variables in TIG welding are welding current, travel speed, arc voltage or arc length, and the shielding gas composition.

Once the TIG welding process is complete, the tungsten and weld puddle are usually cooled off with inert gas, argon. This cooling process is vital since it provides you with safety and protection from unnecessary accidents.

What Do You Need to TIG Weld?

For TIG welding, you will require more than a few pieces of equipment. Here is an overview of the equipment.

1. An Auto-Darkening Helmet

Welding helmets are among the primary necessities for TIG welding since they protect you from burns and sparks. There are two types of helmets: auto-darkening and manual darkening. The auto-darkening helmets are the best to have since they have more advanced features.

Currently, the market provides several types of welding gloves. They include goatskin, cowhide, or flame-resistant gloves. Most TIG welders prefer using goatskin gloves since they are light and flexible. Before getting gloves, do your due diligence to get the ones suitable for your project.

Welding jacket fabrics are the same as those of the welding gloves, and they come with a satisfaction guarantee from the manufacturer. Most welders prefer cowhide jackets to goatskin ones because they are more affordable. A flame-resistant jacket will be a great choice because you need protective gear with heat-resistant characteristics.

4. TIG Goggles

TIG goggles are essential to protect you from harmful radiation. The goggles are suitable for small tasks, but you will need shading lenses for bigger projects that use higher heat.

Welders come in different sizes and types. The best welder to use is the 3-in-1 type. They range from small to industrial-sized and can perform a range of complex jobs.

6. The Gas Tank

During TIG welding, you will require argon as the shield gas to protect your weld pool. If you do not want to purchase a whole tank, you can always rent one.

Most TIG welders come with tungsten rods for the torch, but you will need to purchase more as you continue welding.

8. Grinders, Sander, and Rods

You will also need a grinding wheel to sharpen the tungsten. Alternatively, you can use a bench grinder that comprises a sander. The filler metal rod should be the size of the metal size to be welded.

How Do TIG Welders Work?

If you are familiar with the oxy-acetylene torch, then you will have an easy ride with TIG welding. During the welding process, you will use an electric torch to weld while feeding the filler rod into the molten puddle. The method also provides welders with the capability to soft start and stop, making the process different from other MIG or stick welding processes.

The process also requires a welder to use an accelerator pedal to control the heat, especially while working on a bench. The heat can be controlled using fingertip remotes on the torch.

What's the Difference Between MIG and TIG Welding?

Understanding TIG welding involves breaking down the processes involved in MIG. MIG welding involves continually feeding a cord through a metal wire into the weld you are creating. The cord uses the metal supply to easily combine two metallic objects as the welder's filler material. On the other hand, TIG uses inert tungsten gas to join the two metal objects together and may or may not use filler materials as welding continues.

MIG welding uses consumable filler to combine metal objects. This property makes welding easy when working on larger and thicker metals. TIG welding does not always use filler materials due to heat being generated. You are only required to heat the TIG torch to be extremely hot for you to swiftly weld thinner metals.

When to Use TIG and MIG Welding

The thicker the metal, the harder it will be to join with just a single heating session. For this reason, thick metals are best welded using MIG. A TIG welding torch is not sufficient for this process.

2. What Electrical Conductivity Do You Need?

It would help if you considered how malleable the metal you are welding is. If it is highly malleable, you will need to heat the metal for a longer time, which uses up more energy. For metals that are electrically resistant and get hot faster, you can weld without filler material, making TIG welding the most suitable method.

If you use filler materials during welding, you will end up with a lot of weld splatter. Removing the spatters will be an additional task during smoothening. In this case, direct metal to metal welding is best, making TIG welding the ideal method.

TIG welding is not the best method to use while welding dissimilar metals due to weak bonds between the welds. However, there are instances when you will have to weld different metals. You will go for MIG since it uses a filler material and forms strong bonds on the end product.

When is TIG Welding Commonly Used?

1. Welding Small and Thin Metals

Welding metals such as aluminum are best welded using TIG since it provides the welder with more accuracy. The welder can also perform different actions like decorating the metals. For example, when manufacturing objects that require stylish appearances for the purposes of aesthetics, TIG gets the job done.

2. Precise and Pretty Welds

TIG gives welders more control, allowing you to achieve precision.

3. Variety of DIY Projects

TIG welding's simplicity and ease make it possible to be used by both beginners and experienced welders while working on their DIY projects. Examples of DIY projects include making bicycles, carts, furniture, and shelving.

The Procedure of Completing a TIG Welding Project

Welders can use TIG welding for a variety of metals such as titanium, aluminum, and copper. The method is also essential for completing tricky projects like curving or rounding off any metal object. Below are the steps to follow to complete a TIG welding project.

1. Choose Your Electrode

Always pick an electrode with regards to the type of metals being welded. If you are welding aluminum, the best rod to use is a pure tungsten rod.

2. Prepare the Rod to be Used

Preparing the rod involves grinding it to the desired point of usage. Grinding the rod is usually required, especially if it is brand new, rounded on the tip, or not pointed. By grinding, you'll have reduced the energy used during welding.

3. Place the Electrode into the Collet

This process involves unscrewing the electrode holder and inserting your electrode then screwing it back. You can skip this stage if your electrode is already inside.

4. Select the Settings for TIG Welding

A TIG welding machine provides welders with three options in settings: AC, DCEP, and DCEN. Alternating Current (AC) settings are best used when welding metals such as aluminum. When balling your tip or stick, welding Direct Current Electrode Positive (DCEP) is the most preferred. Welders using steel metals prefer using Direct Current Electrode Negative (DCEN).

The next setting is the "Cleaning/Penetrating" settings to place it on the sharp end. When you are using a scale of 1 to 10, ensure you set it at gauge 7. Switch on the "Air on" for up to 5 seconds and set the "Max Amps" at around 250.

5. Get the Shielding Gas Ready

When welding using aluminum metals, use pure argon for this process and use a mixture of argon and carbon dioxide when welding steel.

6. Get Your Metal and Welding Table Ready

You will require a large metallic area to allow sufficient electricity to flow through the metal. Alternatively, you can use a large, flat sheet of metal in place of a welding table. Scrub off the surfaces using a wire to remove dust and other impurities. Cleaning ensures you end up with prettier and precise welds. Use acetone to wipe the welding rods down.

Ensure you clamp the metals before beginning the welding process to keep the welds in place. Most welders also prefer spraying the welding table with anti-spatter to prevent metal leaks from sticking on the welds.

7. Gearing Up

Gearing up is necessary for your safety and protection against radiation, heat, sunburns, and harmful gases produced during welding. Welders are required to put on thick gloves, a welding helmet, closed-toe shoes, and a welding coat.

8. Do the Final Check

At this stage, you must counter-check if all equipment is in place and functioning optimally. You should also check if your gear is well worn and tucked up as recommended in a welder's manual. Proceed to place the electrode in your dominant hand and test it. While testing, ensure the electrode moves freely and is easy to work with before you begin welding.

TIG Welding for Beginners

To understand the process of TIG welding for beginners, here are the essential tips to consider.

1. Use the Minimum Power

Using too much power can cause the weld to burn hence the need to use minimum power. Using minimal power also allows you to develop a puddle technique suitable for creating strong and stable welds.

2. The Angle of the Torch

When welding, the torch should be at least 15-20 degrees away from the material's surface and electric current flow path. This angling will allow easy access to the filler material and increase visibility on the part being welded.

3. Keep the Welding Materials Clean

Ensure the welding metals are clean for a strong welding arc. Use a wire brush to scrub off dust and other impurities from the metals.

4. Avoid Melting the Filler Rod Directly

Remember the TIG welding principle that the torch melts the base metal while the molten puddle melts the filler material. Direct melting will result in a weak bond on the weld.

5. Wear Protective Gear

Since tungsten electrodes emit low radiation levels, put on shading lenses helmets. You also need to wear a respirator to protect yourself from toxic gases and fumes. Ensure you also weld in a well-ventilated area to reduce the chances of dust from compromising welds' quality.

6. Use the Correct Type of Tungsten

Different types of metals work with varying types of tungsten. Working on aluminum surfaces, use green tungsten and use red tungsten for steel metals.

1. Why Use Tungsten as an Electrode?

Tungsten is usually used due to its high-temperature resistance elements. Their melting points are estimated at around 6170 °F, making them unable to melt during arc welding. They are resistant to corrosion, oxidation and are useful in electric transmission.

2. Which is the best gas for TIG Welding?

The best gas to use is argon, with purity levels as high as 99.967% and low water vapor below 0.005 mg.

Conclusion

Once you know what TIG welding involves, how it is used, and where to use it, you can begin your welding project. If you follow this comprehensive guide, you should be able to come up with beautiful welds whether finessing your profession or enjoying your new hobby.

Featured Image Credit: Lapis2380, Shutterstock

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What is TIG Welding Used for? (& How to Know When to Use It) - WaterWelders

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Last Updated on Have you ever had an interest in welding? You probably have trouble differentiating TIG from MIG welding and when to use either of the two methods. For many years, welders have been using TIG welding to finish projects with thinner metals that MIG could not handle.

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Summary: TIG welding using a non-consumable electrode made of tungsten that is often alloyed with other metals. These different alloys produce a variety of effects on the characteristics and heat capacity of the tungsten. Pure tungsten and %2 thoriated tungsten were the standard for many years until newer developments brought a variety of other alloys that improved upon the originals. The tungsten preparation also has an effect on how it welds. A longer sharpened tip produces a wider arc, whereas a stubbier tip produces a thinner arc. Each has its uses but it is up to the welder to decide what the best preparation is for their weld.

Reflection: Ron Cowell describes many informative aspects of TIG welding in this article that give an explanation to the different types of tungsten electrodes that can be used. It is incredibly useful for deciding the proper tungsten alloy to be used for a chosen weld. For any type of AC welding he suggests that a Ceriated or Zirconiated tungsten would be the best choice. For DC welding, Ceriated is still a good choice but Thoriated or Lanthanated would also work.

Citation: Covell, Ron. “All about Tungsten in Tig Welding: Types, Selection and Use.” Miller Electric, Miller Electric MFG, 5 Oct. 2022, https://www.millerwelds.com/resources/article-library/all-about-tungsten-in-tig-welding-types-selection-and-use.

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Ron Covell Owner, Covell Creative Metalworking

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TIG welding allows the welder more control. Learn from Ron Covell about the different tungsten electrodes available for a variety of welding applications.

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Summary: The TIG welding process is the only process that uses a non-consumable tungsten electrode to create high-quality welds on virtually any metal. TIG electrodes are decided based on the parameters of the job. There are a variety of types of tungsten electrodes that are each good for certain things, for example pure tungsten is good for AC welding on aluminum while 2% Thoriated is best for DC on carbon steel. One significant challenge to TIG welding is its high-difficulty level, it can take years to master TIG welding in any meaningful way.

Reflection: This article gave a lot of detailed information regarding the specifics of a TIG set up. It gave a detailed list of tungsten electrodes and their advantages/disadvantages as well as an explanation of their purposes. This article was very informative regarding both the negative and positive aspects of TIG welding.

Citation: Sild, Siim. “Tig Welding Explained.” Fractory, 9 Jan. 2023, fractory.com/tig-welding-explained/.

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TIG welding is a stable arc welding process that uses a non-consumable tungsten electrode and an inert gas in the welding arc to create high-quality welds. It became a groundbreaking success during the 1940s when it was first used for welding together aluminium and magnesium alloys in the aerospace industry.

While it started out as a solution to manufacture aircrafts, TIG welding eventually became an accelerator in different industries offering unmatched quality. A lot of advancements and innovations in technology have been made since and this process has become irreplaceable in many instances.

So, without further ado, let's delve deeper and discuss what TIG welding is.

What Is TIG Welding?

Tungsten inert gas welding, also known as gas tungsten arc welding (GTAW), is a welding process that joins pieces of metal together through a welding current. An inert gas is supplied to the welding torch that flows along the welding arc to protect the metals from oxidation and from forming small circular gaps. A tungsten electrode is assembled within the welding torch, which has a higher melting point than most metals.

TIG welding is sometimes confused with MIG welding. Although they have their similarities, there are some key differences that need to be pointed out.

Difference Between TIG and MIG Welding

The main difference between MIG and TIG welding processes is that TIG welding uses a non-consumable electrode and separate filler material (optional). While MIG uses a continuous, consumable wire electrode that is automatically fed to the welding gun.

TIG welding is most often performed when joining pipes and thin materials. This is thanks to its low heat input, which preserves the microstructure of the metals. When it comes to thicker materials, MIG (metal inert gas) welding is preferred. Given its lower cost versus other welding processes and its ability for high weld speeds, many resort to using MIG or spot welding for mass production.

TIG rarely creates spatter and typically requires only light polishing to remove any discoloration. It holds an edge over MIG welds when it comes to looks and thus it's preferred when the workpiece is not coated or painted, as is often the case with aluminum and stainless steel. This does not mean that MIG welds can't be aesthetically pleasing but it is rather common for MIG welds to be painted.

Depending on the project, the use of filler metal is optional for TIG welding. When feeding filler rods to the weld pool, TIG welders have to use both hands and control the heat input with the pedal at the same time. All this makes TIG welding a far more challenging process than MIG, where the filler wire is automatically fed from the torch. Most welders generally start out as MIG operators and then transition later into TIG welding.

TIG welding is not simply a plug-and-play process. The primary difference that sets the TIG welder machine apart from the others is its many adjustable features, such as the amperage flow, pulse amount, AC/DC output and inert gas flow. With all these customisable functions available, the process of TIG welding is quite versatile.

TIG Welding Process

The first step in the TIG welding process is to adjust the machine to the right settings, such as the current and voltage, through the rotating knobs on the machine. Next, the correct pressure for the inert gas in the supply tank must be set through a flowmeter regulator. The TIG torch should also be modified according to the project requirements by choosing an electrode with the correct diameter, TIG collet, and other parts. Above everything else, prioritise having clean protective gear to have clear vision while doing welds.

After all the prep work is done, it's time to weld the metals together. Several things should be considered to ensure a smooth flow of operation: the arc length, travel speed, torch angle, and other precautionary measures. TIG welds can run weld beads without filler material, only melting the base metals, but you can use it with filler rods or metal coils if the project requires it to.

Although the internet is filled with so-called TIG cold welding videos and pictures, this method has nothing to do with the actual cold welding process.
It focuses on the appearance of the welds but it actually lacks fusion due to significantly reduced heat input and is rather ineffective in creating strong, permanent joints.

Important Details While Working

1. A proper forward angle is necessary when using the torch to prevent air pocket buildup that creates porosity in the bead.

2. A short arc length should be maintained for optimal control. The electric arc will widen as the arc length is increased.

3. Consistent travel speed is the key to keeping a consistent bead. Increasing the speed will cause a narrowing of the weld bead.

4. Avoid touching the weld pool with the tungsten electrode.

5. The size of the filler metal should be correct and the process of feeding it to the weld must be executed with proper control.

6. The shape of the tungsten electrode's tip should always be consistent. It can be resharpened on a grinding wheel.

Materials in Gas Tungsten Arc Welding

TIG welders can utilise an array of materials. Some of the base materials listed for tungsten inert gas arc welding are:

You need to keep in mind that the process of TIG welding for each material is slightly different. Modifications can range from the size of the electrode diameter down to the electric arc applied in the materials. It is vital that the electrode has the correct diameter and that the amperage applied is correct. The lower the current, the smaller the tip angle and the diameter of the electrode.

Non-Consumable Tungsten Electrode

Tungsten is used in this process since this rare, metallic element intrinsically has a high melting temperature (3422°C) when compared to other metals (e.g. stainless steel has a melting point from 1400 to 1530 ° C). Tungsten offers excellent electrical conductivity without being consumed. Though, erosion can still occur on the tip during the shielded metal arc welding procedure.

Tungsten electrodes can also be alloyed to improve their properties depending on the weld type. Here are some common examples:

Pure tungsten electrode (green) - They offer good arc stability when using AC current. Used for light metals since they keep a clean, balled end. These are also the cheapest and applied for general purpose work.

Thoriated electrodes (1% thorium yellow; 2% red; 3% purple) - Quite common in the welding scene as they were the first to beat pure tungsten electrodes in DC welding arc performance. They have a high current carrying capacity and they maintain the shape of the tip longer. However, thorium emits alpha radiation, which can harm the respiratory system. A dust extraction system is required for collecting the dust during tip grinding.

Lanthaned electrodes (1% lanthanium black, 1.5% gold, 2% blue) - Non-radioactive electrode alloyed with lanthanum oxide. Characterised by excellent arc stability properties with low erosion rate. A bit less efficient than thoriated electrodes.

Ceriated electrodes (2% cerium grey) - Non-radioactive electrode alloyed with cerium oxide. These electrodes have great arc starting but less current capacity than lanthaned electrodes.

Zirconiated electrodes (0.7-0.9% zirconium white, 0.15-0.5% brown) - These electrodes combine tungsten with zirconium oxide. This alloy has a high resistance to contamination and longer electrode life. Produces an extremely stable arc, thus it is used when the highest quality is needed.

Cerium lanthanium electrodes (pink) - A combination of ceriated and lanthaned electrodes offering simplified arc ignition with a long life span.

Inert shielding gas is fed to the TIG torch to keep the weld pool free from contamination while the current is supplied to the welding arc. The shielding gas flow is essential in protecting the weld puddle from oxidation and impurities from the atmosphere while the metals are melted and fused along with the filler rod.

The most common shielding gas used for this process is argon. Other combinations of hydrogen and argon and a mixture of helium and argon are used when other factors are considered (e.g. metals to be welded, welding speed, material penetration etc).

Welding Torch

A welding torch is a mechanical tool specialised in melting and fusing metals. It has several types depending on its use:

Air-cooled TIG torches only have one gas input and are more prone to overheating, unlike water-cooled TIG torches. The primary use of these torches is for thin-walled metals and minor projects.

Water-cooled TIG torches have a gas input while having an input and output for water lines. This is an advantage for larger projects that need rapid cooling. This comes with its price though, as a water cooler system has to be installed.

Power Source

The source of the current in gas tungsten arc welding should be drooping and constant. This allows for stable and consistent heat input. You can also switch between alternating current (AC) to direct current (DC) power source depending on the material type and weld output you desire.

AC vs DC power

There are three options available for the welding current along with its own respective uses:

AC welding uses an alternating current between the positive and negative polarities, maintaining the heat without overheating the base material. Commonly used materials are aluminium and magnesium.

DC power electrode negative uses the negative polarity on the torch to pinpoint the energy flow to the material, much like a hose spraying water on a targeted area. This makes it more appealing to all metals, excluding aluminium and magnesium.

DC power electrode positive is hardly used in TIG welding since the current is flowing towards the electrode, making it ball up from the rapid heat input. The only plus side in DCEP is the presence of a "cleaning action" wherein the oxides in the weld pool's surface give off a shiny appearance.

Another factor to keep in mind is the applied frequency Hz. Lower frequencies create a wider bead with decent penetration, whereas higher frequencies allow for more control and penetration in the weld area.

Advantages of TIG Welding

1. TIG welding can be performed on a wide array of different metals and alloys.

2. A TIG welder has many customisable functions, perfect for specific operations.

3. Applicable to varying types of metal thicknesses and complex metal welding. Although for really thick metals, MIG or stick welding is preferred.

4. A non-consumable electrode and a stable arc allow for greater control and create high-quality TIG welds.

5. Safe gases are used in this gas metal arc welding process, as a result it has fewer weld defects.

6. TIG welding can be performed at awkward angles. An example would be its application in welding overhangs, where the welding torch has to be in a unique position.

7. It is easy to view the workpiece since the shielding gas is colourless with minimal smoke formed.

Disadvantages of TIG Welding

1. TIG welding requires a lot of skill from the operator.

2. Welding time is noticeably longer compared to other welding techniques.

3. Using the wrong polarity can easily contaminate the weld bead.

4. The overall weld strength diminishes when exhibiting a lack of control over the heat input. This also negatively affects the microstructure of the metals.

5. Without a controlled environment, mainly a wind-free environment, it might be difficult to keep a constant gas flow over the weld area.

6. Compared to other welding techniques, the equipment and inert gases are more pricey.

Important Points To Remember

TIG welding offers accurate and good-looking weld beads with good penetration. It is the preferred method for welding aluminium and magnesium alloys, along with many other metals including stainless steel. It is a bit more expensive and slower method when compared to some other types of welding but it is irreplaceable when creating higher quality welds.

Its consistency and versatility allow it to be highly attractive across almost all industries, from professionals to hobbyists alike. Although TIG process can be automated with the use of welding robots, the manual welding process still has quite a steep learning curve and to achieve the best results, it is most often performed by experienced welders.
Fractory's welding services are carried out by our manufacturing partners whose processes have been audited by us to guarantee high-quality welds.

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TIG welding is a stable arc welding process that uses a non-consumable tungsten electrode and an inert gas in the welding arc to create high-quality welds. It became a groundbreaking success during the 1940s when it was first used for welding together aluminium and magnesium alloys in the aerospace industry.

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TIG Welding 101: The Ultimate Guide for Beginners

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TIG Welding 101: The Ultimate Guide for Beginners

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Summary: TIG welding is a simple process that uses a tungsten electrode to create an arc between itself and the base metals. In AC processes the shielding gas is ionized in such a way that it produces a cleaning action that's good for removing oxides on metals like Aluminum and Magnesium. To begin welding the machine first needs to be set up properly, then the pedal is depressed and a gentle arc is lit. After pressing harder on the pedal a pool of molten metal should form on the base plate where the arc meets it. That puddle can then be used to melt filler metal and weld multiple pieces of metal together.

Reflection: I thought this article was very informative and gave many tips for better TIG welding. It also explains the science behind the process and the significance of shielding gas when welding. Overall it provided a good overview of the TIG process as a whole.

Citation:Wilson, Frank. “Tig Welding 101: The Ultimate Guide for Beginners.” TIG Welding 101: The Complete Guide for Beginners, 3 Jan. 2023, simplyweld.com/tig-welding-101-beginners-guide/.

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TIG Welding 101: The Complete Guide for Beginners

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TIG welding is one of the popular method of welding. In this ultimate guide, you can learn how to do TIG welding, tips and everything you need to know.

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Summary: TIG welding was invented in 1940 by Russel Meredith, at that point it was heliarc welding due to the exclusive use of helium in the process. The patent was purchased by the Linde Division of Union Carbide who then produced components and accessories for the process until the early 1970s when the patent expired. After that many companies took over production, the lead of which was CK worldwide.

Reflection: This article gives good information on the technicalities of TIG welding history. Giving details about companies and production processes that led to the development of the TIG machines we use today.

Citation: French, Curtis. “The History of Tig Welding.” PrimeWeld, 2023, primeweld.com/blogs/news/the-evolution-of-tig-welding.

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Learn more about how the Tungsten Inert Gas (TIG) welder has evolved over the years. Get TIG welding information & more with PrimeWeld.

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Summary: Welding began during the bronze age, in its most basic form of heat and hammering. But in the 18th century a man named Sir Humphrey Davey created the first arc between two carbon electrodes using a car battery. This marked the start of modern arc welding. Many different people then went on to discover different types of welding finally leading to the invention of TIG welding in 1941 by a man named Russel Meredith.

Reflection: This article gave me a step by step guide to the history of welding as a whole. It gave exceptional descriptions of events and significant scientific discoveries that lead to each new technique. The article even included a organized time line of all metallurgy developments since the bronze age.

Citation: Mason, Adam. “Welding History: Events That Marked the Age of Welding.” WeldingPros, 10 May 2022, weldingpros.net/welding-through-history/.

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WeldingPros - Welding Career Guide, How To and Gear Reviews

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What Was The History Behind Welding?

The history of humankind is closely related to the discovery of metals, progressing from copper, bronze, silver, gold, and iron. Finally, the ancestors started wondering whether you could join the two pieces of metal, so they started forming and shaping metals, leading to the first traces of metalworking.

So during this period, Egyptians and the people in the eastern Mediterranean mastered shaping it. First, they used charcoal-generated heat to turn iron ore into direct reduced iron, also called sponge iron. Afterward, they hammered the product into different shapes, most commonly weapons.

Approximately around 1500 BC, there were instances of iron smelting, which became more common in 1200 BC. Later on, Egyptians started making iron tools and even more powerful weapons. After that, iron joining and welding became popular across the globe, as various civilizations used it for sculptures such as ones in Delhi, India, Sui Dynasty in China, and all across Europe.

When Was Welding Invented?

Who Invented Welding?

We can't credit a single person for inventing the welding, as it was perfected through the years by several scientists and inventors.

As mentioned above, in 1800, Sir Humphrey Davy invented the electric arc, and Edmund Davy of England was credited with the discovery of acetylene in 1837. However, acetylene was not practical in welding until approximately the 1900s.

Later on, welding processes advanced rapidly. First, Nikolai Slavynov figured out how to use metal electrodes for welding. Following this, C.L. Coffin, an American engineer, discovered an arc welding process and became the precursor of shielded metal arc welding.

When Was Arc Welding Invented?

C.L. Coffin of Detroit was awarded the first U.S. patent for the arc welding process in 1890. He was a pioneer of welding in the U.S., credited for creating the first bare electrode. To make a weld, he used the metal that melted from the electrode, which was carried across the arc and deposited into a joint.

Unaware of his fellow scientist's work, a Russian Nikolay Slavyanov presented the same idea of transferring metal across an arc. However, compared to his colleague's work, the cast metal was transferred in a mold. Still, the year 1888 is milestoned as a discovery of Stick/Arc welding. However, the first electrodes were bare, resulting in poor arc performance.

To deal with this issue, scientists started working on coated electrodes. Approximately 1900, Strohmenger introduced a coated metal electrode. The coating was fragile and made of clay or lime but still provided a more stable arc. Then, between 1907 and 1914, Oscar Kjellberg of Sweden within the company ESAB (Elektriska Svetsnings-AtkieBolaget) coated electrode by dipping bare iron wire in thick mixtures of carbonates and silicates.

The Arc welding industry in the U.S. starts with two companies. The Siegmund-Wienzell Electric Welding Co. and Enderlein Electric Welding Co.

More on Arc welding here.

When Was Resistance Welding Invented?

Who Invented Gas Welding and Cutting?

The invention of gas welding played a significant part in the shipbuilding and aerospace industry of the 20th century. Welding increased productivity and reduced the weight and time required to build a ship. In addition, gas welding was cheap, and the heat was moderate so that the thin plates wouldn't bend when joining.

What Was The First Welding Company?

Was Titanic Welded or Riveted?

Another victim of the brittle fracture was the ship SS Schenectady. In 1943, the haul of the vessel cracked nearly in half, just aft of the superstructure. Defective welding was the most common explanation for this incident. However, later research showed that low-grade steel was responsible.

Welding During WWI

By WWI, spot welding, resistance welding, and seam welding were being done. The tremendous demand for armament production and welding was pressed into service as the many companies around America and Europe started growing.

In addition, backing materials could catch splinters, though this was less important by WWII, thanks to changes in armor metallurgy. To prevent an arms race after WWI, The Washingon Naval Treaty was signed. In November 1921, representatives agreed to limit the construction of battleships, battlecruisers, and aircraft carriers. However, the production wasn't limited by numbers but by weight of 10,000 tons displacement. In addition, the treaty resulted in increased use of welding in shipbuilding.

Welding the ship plates resulted in fewer rivets and bolts, which reduced the overall weight of the ships. Thus, manufacturers could add more arms following the treaty margins by welding in shipbuilding without surpassing the treaty guidelines.

Welding Inventions During The 1920s

World War I bestowed the world with the importance of welding, which resulted in increased popularity and many essential breakthroughs.

Automatic Welding Invention

The process was designed to make longitudinal seams in the pipe. Robinoff patented the submerged arc welding process in 1930, which was later sold to Linder Air Products Company.

Shielding Gas Research

With the increased popularity of welding, inventors had to deal with brittle and sometimes porous welds. In addition, the nature of the atmosphere caused oxygen and nitrogen to affect the sturdiness of molten metal that was forming the weld.

Noticeable research in shielding the arc and weld area was done during the 1920s. Scientists Alexander and Langmuir worked in chambers where they used hydrogen as a welding atmosphere. The hydrogen was changed into atomic hydrogen, shielding the arc, finally resulting in atomic hydrogen welding. However, this process was used only in particular applications.

Nevertheless, working in specific welding atmospheres inspired other inventors. That's why H.M. Hobart and P.K. Devers used argon and helium welding atmospheres to do the research. The research resulted in a 1926 patent, where arc welding utilized external gas supplied around the arc. This patent was a pioneer of the GTAW process. In addition, researchers also used a concentric nozzle with the constant electrode feed, which was a forerunner of the GMAW welding process.

What Was The First Welded Ship?

Welding had been introduced in American ships before 1918, although none had an entirely welded hull. Riveted ships were solid and durable, but riveted hulls had drawbacks. The time needed to align steel plates, drill holes for rivets, and set and drive home the bolts was significant.

The garbage lighter (YG-16) was the Navy's first ship to be built with an all-welded hull. The ship would go by many names but was often referred to as the "Honey Barge." In 1930 at the New York Navy Yard, stud welding was developed. The process was mainly perfected for attaching wood decking over a metal surface. That's why stud welding became popular in the shipbuilding and construction industries.

Poughkeepsie Socony is one of the initial units in the Soeony-Vacuum Oil Company's $5,000,000 shipbuilding program. Socony was the largest all-welded merchant vessel ever built in 1934 in the United States and probably worldwide.

The First Welded Bridge

The first welded bridge was a small railway bridge built in Turtle Creek 1927 in Pennsylvania, designed and made as a plate girder structure. The second (also railway) welded bridge was constructed in Chicopee Falls (in 1928) in Massachusetts.

However, if confronted with present requirements, the quality of the welded joints in the firstly built bridges is relatively low. Yet, considering the level of welding techniques in the late 1920s, the assessment should be positive.

Most highway bridges in the US were built in the 1950s and 60s after President Eisenhower's Federal Highway Act. During the 1950s, arc welding was used increasingly in the fabrication and erection of highway bridges. However, the U.S. Department of Transportation estimates one in four is considered structurally deficient or functionally obsolete of those bridges.

What Is The First Welded Building?

The first all-welded multistory buildings were a series of factories for the Westinghouse Company. Starting in 1920, the welded rigid frame became a new structural type for medium spans, but the widespread use of welding did not come until after 1945.

The Upper Carnegie Building in Cleveland was the first commercial building wholly constructed from arc-welded steel. Lincoln Electric company, with an architectural firm, completed the first commercial building in 1928.

Pipeline Welding Evolution

However, by 1948, this process was superseded by the double submerged-arc process. In the 1960s, steel making underwent further significant improvements, pipe manufacturing technology continued to evolve.

Female Welders During The WWII

Not so long after WWII, the world was called to arms once again. Once the U.S. became involved in WWII after Pearl Harbor, thousands of capable men left their jobs. With so many job openings, the women of America stepped up to the plate to prove themselves.

Rosie the Riveter was an allegorical cultural icon of World War II, representing the women who worked in factories and shipyards. Rosie the Riveter inspired a social movement that increased the number of working American women from 12 million to 20 million by 1944, a 57% increase from 1940.

With a distinctive helmet, the woman welder symbolized a changing world. Winnie the Welder became a familiar figure, appearing in advertisements, recruiting posters, and cartoons. But over time, her stature in popular imagination dimmed.

Brief History of TIG Welding

Linde company developed the first TIG welding machines and sold various torches, parts, and consumables. These massive units weighed hundreds of pounds, but technological progress made them smaller. Then, in the 1970s, the Miller corporation introduced the square waveform feature that allowed for better control of amperage.

To learn more on TIG welding jump to these articles : ( 1), ( 2)

Brief History Of MIG Welding

Scientists Lyubavskii and Novoshilov made a significant breakthrough in 1953 by introducing consumable electrodes and a CO2 welding atmosphere. CO2 welding gained tremendous popularity since it utilized inert gas metal arc equipment, but it was a much more economical option in welding steel.

In late 1958 and early 1959, inventors developed the short-circuit arc variation, also known as micro-wire, short-arc, and dip transfer welding. Later on, in the 1960s, experimenters introduced a spray-arc transfer and pulsed current. As a result, a new method called pulsed spray-arc arose.

To learn more on MIG welding you read this article

Flux-core Electrodes Invention

After introducing the CO2 gas into welding, inventors went even further. To ensure the best weld quality, experimenters introduced shielded electrodes to work alongside shielding gas. The tubular inside-outside electrode featured fluxing agents inside and the shielding gas outside, so the whole process was called Dualshield. The Dualshield process was invented by Bernard and announced in 1954 and patented in 1957.

Further research introduced an inside-outside electrode that didn't require external gas shielding. Finally, in 1959, Innershield electrodes were presented and gained popularity.

Welding Processes of 20th Century

In 1958, the Soviets announced the Electroslag welding process. However, the process has been widely used in the Soviet Union since 1951. Nevertheless, the idea is based on the work of R.K. Hopkins, who got patents in 1940.

A variation of Electroslag welding was introduced in 1961 by the Arcos Corporation. The Electrogas welding process utilized the same equipment as Electroslag welding, but external shielding gas and flux-core electrode was introduced.

In 1957, Gage introduced the plasma arc welding process. The plasma arc heat was significantly higher than the tungsten arc temperature.

J.A. Stohr of the French Atomic Energy Commission introduced the electron beam welding process in 1957. The method uses a focused beam of electrons as a heat source. Electron beam welding was found essential to use in the aircraft engine and automotive industries of the US.

Welding Codes And Standards

In 1976, AWS published AWS D1, the must-have welding code for every welder. The principle dictates the requirements for design, procedures, qualifications, fabrication, inspection, and repair of steel structures made of tubes, plates, and structural shapes subject to static or cyclic loading.
All the codes are updated to suit the guidelines of the modern industry.

New Welding Technologies in Welding Industry

In the 21st century, welding has become one of the essential trades in the industry. Following the rise of popularity, various researchers and inventors are still working on perfecting new gear, welding processes, and technologies.

As a result, welding machines are technologically advanced, while welding has become even easier to perfect. Even though inventors introduced various welding processes over time, Stick, MIG, and TIG welding are widely used. Combined with Plasma cutting, many small autobody shops, farm, and minor repair businesses arose.

On the other hand, to increase productivity and reduce costs, the industry is still perfecting welding. As a result, we have new welding technologies, robotic welding, and improved protective equipment.

Laser Welding Technology Improvements

Laser welding is one of the unique types of welding processes that was recently inaugurated. Powerful lasers instantly melt and join metals together. For example, lab research showed that powerful lasers could immediately weld 50mm thick steel.

However, technology is still facing some issues. Now, lasers are still dealing with energy efficiency, requiring significantly more power to weld thicker materials.

Nevertheless, laser welding found substantial use in the automated car manufacturing industry. Still, the idea around laser welding will for sure be a hot topic in years to come.

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Welding History: Events That Marked The Age Of Welding

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The history of humankind is closely related to the discovery of metals, progressing from copper, bronze, silver, gold, and iron. Finally, the ancestors started wondering whether you could join the two pieces of metal, so they started forming and shaping metals, leading to the first traces of metalworking.